Surgical instrument battery pack with power profile emulation

ABSTRACT

A method of operating a medical device comprises connecting a secondary battery pack to the medical device. The secondary battery pack includes a processor configured to emulate at least one electrical characteristic of a primary battery pack that has at least one different electrical characteristic than the secondary battery pack. The method further comprises receiving an interrogation input from the medical device with the processor of the secondary battery pack. The method further comprises sending a response output to the interrogation from the processor to the medical device. The response output emulates an expected response output associated with the at least one different electrical characteristic of the primary battery pack. The method further comprises initiating an operational profile associated with the medical device.

BACKGROUND

In some settings, endoscopic surgical instruments may be preferred overtraditional open surgical devices since a smaller incision may reducethe post-operative recovery time and complications. Consequently, someendoscopic surgical instruments may be suitable for placement of adistal end effector at a desired surgical site through the cannula of atrocar. These distal end effectors may engage tissue in a number of waysto achieve a diagnostic or therapeutic effect (e.g., endocutter,grasper, cutter, stapler, clip applier, access device, drug/gene therapydelivery device, and energy delivery device using ultrasonic vibration,RF, laser, etc.). Endoscopic surgical instruments may include a shaftbetween the end effector and a handle portion, which is manipulated bythe clinician. Such a shaft may enable insertion to a desired depth androtation about the longitudinal axis of the shaft, thereby facilitatingpositioning of the end effector within the patient. Positioning of anend effector may be further facilitated through inclusion of one or morearticulation joints or features, enabling the end effector to beselectively articulated or otherwise deflected relative to thelongitudinal axis of the shaft.

Examples of endoscopic surgical instruments include surgical staplers.Some such staplers are operable to clamp down on layers of tissue, cutthrough the clamped layers of tissue, and drive staples through thelayers of tissue to substantially seal the severed layers of tissuetogether near the severed ends of the tissue layers. Merely exemplarysurgical staplers are disclosed in U.S. Pat. No. 4,805,823, entitled“Pocket Configuration for Internal Organ Staplers,” issued Feb. 21,1989; U.S. Pat. No. 5,415,334, entitled “Surgical Stapler and StapleCartridge,” issued May 16, 1995; U.S. Pat. No. 5,465,895, entitled“Surgical Stapler Instrument,” issued Nov. 14, 1995; U.S. Pat. No.5,597,107, entitled “Surgical Stapler Instrument,” issued Jan. 28, 1997;U.S. Pat. No. 5,632,432, entitled “Surgical Instrument,” issued May 27,1997; U.S. Pat. No. 5,673,840, entitled “Surgical Instrument,” issuedOct. 7, 1997; U.S. Pat. No. 5,704,534, entitled “Articulation Assemblyfor Surgical Instruments,” issued Jan. 6, 1998; U.S. Pat. No. 5,814,055,entitled “Surgical Clamping Mechanism,” issued Sep. 29, 1998; U.S. Pat.No. 6,978,921, entitled “Surgical Stapling Instrument Incorporating anE-Beam Firing Mechanism,” issued Dec. 27, 2005; U.S. Pat. No. 7,000,818,entitled “Surgical Stapling Instrument Having Separate Distinct Closingand Firing Systems,” issued Feb. 21, 2006; U.S. Pat. No. 7,143,923,entitled “Surgical Stapling Instrument Having a Firing Lockout for anUnclosed Anvil,” issued Dec. 5, 2006; U.S. Pat. No. 7,303,108, entitled“Surgical Stapling Instrument Incorporating a Multi-Stroke FiringMechanism with a Flexible Rack,” issued Dec. 4, 2007; U.S. Pat. No.7,367,485, entitled “Surgical Stapling Instrument Incorporating aMultistroke Firing Mechanism Having a Rotary Transmission,” issued May6, 2008; U.S. Pat. No. 7,380,695, entitled “Surgical Stapling InstrumentHaving a Single Lockout Mechanism for Prevention of Firing,” issued Jun.3, 2008; U.S. Pat. No. 7,380,696, entitled “Articulating SurgicalStapling Instrument Incorporating a Two-Piece E-Beam Firing Mechanism,”issued Jun. 3, 2008; U.S. Pat. No. 7,404,508, entitled “SurgicalStapling and Cutting Device,” issued Jul. 29, 2008; U.S. Pat. No.7,434,715, entitled “Surgical Stapling Instrument Having MultistrokeFiring with Opening Lockout,” issued Oct. 14, 2008; U.S. Pat. No.7,721,930, entitled “Disposable Cartridge with Adhesive for Use with aStapling Device,” issued May 25, 2010; U.S. Pat. No. 8,408,439, entitled“Surgical Stapling Instrument with An Articulatable End Effector,”issued Apr. 2, 2013; and U.S. Pat. No. 8,453,914, entitled “Motor-DrivenSurgical Cutting Instrument with Electric Actuator Directional ControlAssembly,” issued Jun. 4, 2013. The disclosure of each of theabove-cited U.S. Patents is incorporated by reference herein.

While the surgical staplers referred to above are described as beingused in endoscopic procedures, it should be understood that suchsurgical staplers may also be used in open procedures and/or othernon-endoscopic procedures. By way of example only, a surgical staplermay be inserted through a thoracotomy, and thereby between a patient'sribs, to reach one or more organs in a thoracic surgical procedure thatdoes not use a trocar as a conduit for the stapler. Such procedures mayinclude the use of the stapler to sever and close a vessel leading to alung. For instance, the vessels leading to an organ may be severed andclosed by a stapler before removal of the organ from the thoraciccavity. Of course, surgical staplers may be used in various othersettings and procedures.

Examples of surgical staplers that may be particularly suited or usethrough a thoracotomy are disclosed in U.S. Patent ApplicationPublication No. 2014/0243801, entitled “Surgical Instrument End EffectorArticulation Drive with Pinion and Opposing Racks,” published on Aug.28, 2014; U.S. Patent Application Publication No. 2014/0239041, entitled“Lockout Feature for Movable Cutting Member of Surgical Instrument,”Published Aug. 28, 2014; U.S. Patent Application Publication No.2014/0239042, entitled “Integrated Tissue Positioning and Jaw AlignmentFeatures for Surgical Stapler,” published Aug. 28, 2014; U.S. PatentApplication Publication No. 2014/0239036, entitled “Jaw Closure Featurefor End Effector of Surgical Instrument,” Published Aug. 28, 2014; U.S.Patent Application Publication No. 2014/0239040, entitled “SurgicalInstrument with Articulation Lock having a Detenting Binary Spring,”published Aug. 24, 2014; U.S. Patent Application Publication No.2014/0239043, entitled “Distal Tip Features for End Effector of SurgicalInstrument,” published Aug. 28, 2014; U.S. Patent ApplicationPublication No. 20140239037, entitled “Staple Forming Features forSurgical Stapling Instrument,” filed Aug. 28, 2014; U.S. PatentApplication Publication No. 2014/0239038, entitled “Surgical Instrumentwith Multi-Diameter Shaft,” published Aug. 28, 2014; and U.S. PatentApplication Publication No. 2014/0239044, entitled “InstallationFeatures for Surgical Instrument End Effector Cartridge,” published Aug.28, 2014. The disclosure of each of the above-cited U.S. PatentApplications is incorporated by reference herein.

While various kinds of surgical stapling instruments and associatedcomponents have been made and used, it is believed that no one prior tothe inventor(s) has made or used the invention described in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention,and, together with the general description of the invention given above,and the detailed description of the embodiments given below, serve toexplain the principles of the present invention.

FIG. 1 depicts a perspective view of an exemplary surgical instrumentincluding an interchangeable shaft assembly and a handle assembly;

FIG. 2 depicts an perspective view of the instrument of FIG. 1, showingthe shaft assembly disassembled from the handle assembly of theinstrument;

FIG. 3A depicts another perspective view of the instrument of FIG. 1,showing the shaft assembly disassembled from the handle assembly of theinstrument;

FIG. 3B depicts a schematic view of certain components of the instrumentof FIG. 1;

FIG. 4 depicts an exploded perspective view of certain portions of thehandle assembly of the instrument of FIG. 1;

FIG. 5 depicts an exploded front perspective view of certain portions ofthe shaft assembly of FIG. 1;

FIG. 6 depicts a perspective view of an end effector of the instrumentof FIG. 1, with the end effector in a closed configuration;

FIG. 7 depicts a perspective view of the end effector of FIG. 6, withthe end effector in an open configuration;

FIG. 8 depicts an exploded perspective view of the end effector of FIG.6;

FIG. 9 depicts a cross-sectional end view of the end effector of FIG. 6,taken along line 9-9 of FIG. 7;

FIG. 10A depicts a cross-sectional side view of the end effector of FIG.6, taken along line 10-10 of FIG. 7, with the firing beam in a proximalposition;

FIG. 10B depicts a cross-sectional side view of the end effector of FIG.6, taken along line 10-10 of FIG. 7, with the firing beam in a distalposition;

FIG. 11 depicts a perspective view of the end effector of FIG. 6,positioned at tissue and having been actuated once in the tissue;

FIG. 12-1 depicts a first portion of a circuit diagram of the surgicalinstrument of FIG. 1;

FIG. 12-2 depicts a second portion of a circuit diagram of the surgicalinstrument of FIG. 1;

FIG. 13 depicts a block diagram of the surgical instrument of FIG. 1,showing interfaces between the handle assembly and the power assemblyand interfaces between the handle assembly and shaft assembly;

FIG. 14 depicts a power management module of the surgical instrument ofFIG. 1;

FIG. 15 depicts a block diagram of the surgical instrument of FIG. 1,showing an interface between the interchangeable working assembly andthe power assembly;

FIG. 16 depicts a block diagram showing a module of the surgicalinstrument of FIG. 1;

FIG. 17 depicts an exemplary circuit diagram of an alternative exemplarypower assembly of the surgical instrument of FIG. 1;

FIG. 18 depicts an exemplary alternative circuit diagram of the powerassembly of the surgical instrument of FIG. 1;

FIG. 19 depicts an exemplary circuit diagram of the interchangeableworking assembly of the surgical instrument of FIG. 1;

FIG. 20 depicts a block diagram showing an exemplary module of thesurgical instrument of FIG. 1;

FIG. 21A depicts a graphical representation of a voltage signalgenerated by a working assembly controller of the interchangeableworking assembly of the surgical instrument of FIG. 1;

FIG. 21B depicts a graphical representation of a current signalgenerated by a working assembly controller of the interchangeableworking assembly of the surgical instrument of FIG. 1;

FIG. 21C depicts a graphical representation of effective motordisplacement of a motor of the interchangeable working assembly of FIG.1 in response to the voltage signal generated by the working assemblycontroller of FIG. 21A;

FIG. 22 depicts a circuit diagram for an exemplary power assembly of theinstrument of FIG. 1;

FIG. 23 depicts a plot of voltage versus resistance for the battery packof FIG. 22;

FIG. 24 depicts a schematic diagram of an exemplary circuit for anexemplary alternative power assembly of the instrument of FIG. 1;

FIG. 25 depicts a flow chart showing steps carried out during one ormore exemplary methods of utilizing the circuit of FIG. 24;

FIG. 26 depicts a schematic diagram of another exemplary circuit foranother exemplary alternative power assembly of the instrument of FIG.1;

FIG. 27 depicts a flow chart showing steps carried out during one ormore exemplary methods of utilizing the circuit of FIG. 26;

FIG. 28-1 depicts a first portion of a flow chart showing steps carriedout during one or more exemplary methods of utilizing the circuit ofFIG. 26;

FIG. 28-2 depicts a second portion of a flow chart showing steps carriedout during one or more exemplary methods of utilizing the circuit ofFIG. 26;

FIG. 29 depicts a schematic diagram of another exemplary circuit for aportion of an alternative exemplary power assembly of the instrument ofFIG. 1; and

FIG. 30 depicts a flow chart showing steps carried out during one ormore exemplary methods of utilizing the circuit of FIG. 29.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the invention may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presentinvention, and together with the description serve to explain theprinciples of the invention; it being understood, however, that thisinvention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention shouldnot be used to limit the scope of the present invention. Other examples,features, aspects, embodiments, and advantages of the invention willbecome apparent to those skilled in the art from the followingdescription, which is by way of illustration, one of the best modescontemplated for carrying out the invention. As will be realized, theinvention is capable of other different and obvious aspects, all withoutdeparting from the invention. Accordingly, the drawings and descriptionsshould be regarded as illustrative in nature and not restrictive.

I. Exemplary Surgical Instrument

FIGS. 1-6 depict a motor-driven surgical cutting and fasteninginstrument (10) that may or may not be reused. In the illustratedembodiment, the instrument (10) includes a housing (12) that comprises ahandle assembly (14) that is configured to be grasped, manipulated andactuated by the clinician. The housing (12) is configured for operableattachment to an interchangeable shaft assembly (200) that has asurgical end effector (300) operably coupled thereto that is configuredto perform one or more surgical tasks or procedures. As the presentDetailed Description proceeds, it will be understood that the variousunique and novel arrangements of the various forms of interchangeableshaft assemblies disclosed herein may also be effectively employed inconnection with robotically-controlled surgical systems. Thus, the term“housing” may also encompass a housing or similar portion of a roboticsystem that houses or otherwise operably supports at least one drivesystem that is configured to generate and apply at least one controlmotion that could be used to actuate the interchangeable shaftassemblies disclosed herein and their respective equivalents. The term“frame” may refer to a portion of a handheld surgical instrument. Theterm “frame” may also represent a portion of a robotically controlledsurgical instrument and/or a portion of the robotic system that may beused to operably control a surgical instrument. For example, theinterchangeable shaft assemblies disclosed herein may be employed withvarious robotic systems, instruments, components and methods disclosedin U.S. Patent Application Publication No. US 2012/0298719, entitled“Surgical Stapling Instruments With Rotatable Staple DeploymentArrangements,” published Nov. 29, 2012, which is incorporated byreference herein in its entirety.

The housing (12) depicted in FIGS. 1-3A is shown in connection with aninterchangeable shaft assembly (200) that includes an end effector (300)comprising a surgical cutting and fastening device that is configured tooperably support a surgical staple cartridge (1070) therein. The housing(12) may be configured for use in connection with interchangeable shaftassemblies that include end effectors that are adapted to supportdifferent sizes and types of staple cartridges, have different shaftlengths, sizes, and types, etc. In addition, the housing (12) may alsobe effectively employed with a variety of other interchangeable shaftassemblies including those assemblies that are configured to apply othermotions and forms of energy such as, for example, radio frequency (RF)energy, ultrasonic energy and/or motion to end effector arrangementsadapted for use in connection with various surgical applications andprocedures. Furthermore, the end effectors, shaft assemblies, handles,surgical instruments, and/or surgical instrument systems can utilize anysuitable fastener, or fasteners, to fasten tissue. For instance, afastener cartridge comprising a plurality of fasteners removably storedtherein can be removably inserted into and/or attached to the endeffector of a shaft assembly.

A. Exemplary Handle Assembly

FIG. 1 illustrates the handle assembly (14) with an interchangeableshaft assembly (200) operably coupled thereto. FIGS. 2 and 3A illustrateattachment of the interchangeable shaft assembly (200) to the housing(12) of handle assembly (14). As can be seen in FIG. 4, the handleassembly (14) may comprise a pair of interconnectable handle housingsegments (16, 18) that may be interconnected by screws, snap features,adhesive, etc. In the illustrated arrangement, the handle housingsegments (16, 18) cooperate to form a pistol grip portion (19) that canbe gripped and manipulated by the clinician. As will be discussed infurther detail below, the handle assembly (14) operably supports aplurality of drive systems therein that are configured to generate andapply various control motions to corresponding portions of theinterchangeable shaft assembly that is operably attached thereto.

The handle assembly (14) may further include a frame (20) that operablysupports a plurality of drive systems. For example, the frame (20) canoperably support a “first” or closure drive system, generally designatedas (30), which may be employed to apply closing and opening motions tothe interchangeable shaft assembly (200) that is operably attached orcoupled thereto. In at least one example, the closure drive system (30)may include an actuator in the form of a closure trigger (32) that ispivotally supported by the frame (20). More specifically, as illustratedin FIG. 4, the closure trigger (32) is pivotally coupled to the housing(14) by a pin (33). Such arrangement enables the closure trigger (32) tobe manipulated by a clinician such that when the clinician grips thepistol grip portion (19) of the handle assembly (14), the closuretrigger (32) may be easily pivoted from a starting or “unactuated”position to an “actuated” position and more particularly to a fullycompressed or fully actuated position. The closure trigger (32) may bebiased into the unactuated position by spring or other biasingarrangement (not shown). In various examples, the closure drive system(30) further includes a closure linkage assembly (34) that is pivotallycoupled to the closure trigger (32). The closure linkage assembly (34)may include a first closure link (36) and a second closure link (38)that are pivotally coupled to the closure trigger (32) by a pin (35).The second closure link (38) may also be referred to herein as an“attachment member” and include a transverse attachment pin (37).

Still referring to FIG. 4, it can be observed that the first closurelink (36) may have a locking wall or end (39) thereon that is configuredto cooperate with a closure release assembly (60) that is pivotallycoupled to the frame (20). In at least one example, the closure releaseassembly (60) may comprise a release button assembly (62) that has adistally protruding locking pawl (64) formed thereon. The release buttonassembly (62) may be pivoted in a counterclockwise direction by arelease spring (not shown). As the clinician depresses the closuretrigger (32) from its unactuated position toward the pistol grip portion(19) of the handle assembly (14), the first closure link (36) pivotsupwardly to a point wherein the locking pawl (64) drops into retainingengagement with the locking wall (39) on the first closure link (36)thereby preventing the closure trigger (32) from returning to theunactuated position. Thus, the closure release assembly (60) serves tolock the closure trigger (32) in the fully actuated position. Theselocking features may be released by actuation of release button assembly(62). Release button assembly (62) is configured and positioned to beactuated by the thumb of the operator hand that grasps pistol grip (19).In other words, the operator may grasp pistol grip (19) with one hand,actuate closure trigger (32) with one or more fingers of the same hand,and then actuate release button assembly (62) with the thumb of the samehand, without ever needing to release the grasp of pistol grip (19) withthe same hand. When the clinician desires to unlock the closure trigger(32) to permit it to be resiliently driven back to the unactuatedposition, the clinician simply pivots the closure release buttonassembly (62) such that the locking pawl (64) is moved out of engagementwith the locking wall (39) on the first closure link (36). When thelocking pawl (64) has been moved out of engagement with the firstclosure link (36), the closure trigger (32) may pivot back to theunactuated position. Other closure trigger locking and releasearrangements may also be employed.

Further to the above, FIG. 1 illustrates the closure trigger (32) in itsunactuated position which is associated with an open, or unclamped,configuration of the shaft assembly (200) in which tissue can bepositioned between the jaws of the shaft assembly (200). It will beappreciated that the closure trigger (32) may be moved or actuated to anactuated position (not shown) which is associated with a closed, orclamped, configuration of the shaft assembly (200) in which tissue isclamped between the jaws of the shaft assembly (200). It will be furtherappreciated that when the closure trigger (32) is moved from itsunactuated position to its actuated position, the closure release button(62) is pivoted between a first position and a second position. Therotation of the closure release button (62) can be referred to as beingan upward rotation. However, at least a portion of the closure releasebutton (62) is being rotated toward the circuit board (100).

Referring to FIG. 4, the closure release button (62) can include an arm(61) extending therefrom and a magnetic element (63), such as apermanent magnet, for example, mounted to the arm (61). When the closurerelease button (62) is rotated from its first position to its secondposition, the magnetic element (63) can move toward the circuit board(100). The circuit board (100) can include at least one sensorconfigured to detect the movement of the magnetic element (63). In atleast one embodiment, a Hall Effect sensor (not shown), for example, canbe mounted to the bottom surface of the circuit board (100). The HallEffect sensor can be configured to detect changes in a magnetic fieldsurrounding the Hall Effect sensor caused by the movement of themagnetic element (63). The Hall Effect sensor can be in signalcommunication with a microcontroller, for example, which can determinewhether the closure release button (62) is in its first position, whichis associated with the unactuated position of the closure trigger (32)and the open configuration of the end effector, its second position,which is associated with the actuated position of the closure trigger(32) and the closed configuration of the end effector, and/or anyposition between the first position and the second position.

In at least one example, the handle assembly (14) and the frame (20) mayoperably support another drive system referred to herein as a firingdrive system (80) that is configured to apply firing motions tocorresponding portions of the interchangeable shaft assembly attachedthereto. The firing drive system may (80) also be referred to herein asa “second drive system”. The firing drive system (80) may employ anelectric motor (82), located in the pistol grip portion (19) of thehandle assembly (14). In various forms the motor (82) may be a DCbrushed driving motor having a maximum rotation of, approximately,25,000 RPM, for example. In other arrangements, the motor may include abrushless motor, a cordless motor, a synchronous motor, a stepper motor,or any other suitable electric motor. The motor (82) may be powered by apower source (90) that in one example may comprise a removable powerpack (92). For example, the power pack (92) may comprise a proximalhousing portion (94) that is configured for attachment to a distalhousing portion (96). The proximal housing portion (94) and the distalhousing portion (96) are configured to operably support a plurality ofbatteries (98) therein. Batteries (98) may each comprise, for example, aLithium Ion (“LI”) or other suitable battery. The distal housing portion(96) is configured for removable operable attachment to a controlcircuit board assembly (100) that is also operably coupled to the motor(82). A number of batteries (98) may be connected in series may be usedas the power source for the surgical instrument (10). In addition, thepower source (90) may be replaceable and/or rechargeable. Variousalternative forms that power source (90) may take will be described ingreater detail below.

As outlined above with respect to other various examples, the electricmotor (82) can include a rotatable shaft (not shown) that operablyinterfaces with a gear reducer assembly (84) that is mounted in meshingengagement with a with a set, or rack, of drive teeth (122) on alongitudinally-movable drive member (120). In use, a voltage polarityprovided by the power source (90) can operate the electric motor (82) ina clockwise direction. The voltage polarity applied to the electricmotor by the battery can be reversed in order to operate the electricmotor (82) in a counterclockwise direction. When the electric motor (82)is rotated in one direction, the drive member (120) will be axiallydriven in the distal direction “DD”. When the motor (82) is driven inthe opposite rotary direction, the drive member (120) will be axiallydriven in a proximal direction “PD”. The handle assembly (14) caninclude a switch that can be configured to reverse the polarity appliedto the electric motor (82) by the power source (90). As with the otherforms described herein, the handle assembly (14) can also include asensor that is configured to detect the position of the drive member(120) and/or the direction in which the drive member (120) is beingmoved.

Actuation of the motor (82) can be controlled by a firing trigger (130)that is pivotally supported on the handle assembly (14). The firingtrigger (130) may be pivoted between an unactuated position and anactuated position. The firing trigger (130) may be biased into theunactuated position by a spring (132) or other biasing arrangement suchthat when the clinician releases the firing trigger (130), it may bepivoted or otherwise returned to the unactuated position by the spring(132) or biasing arrangement. In at least one form the firing trigger(130) can be positioned “outboard” of the closure trigger (32) as wasdiscussed above. In the present example, a firing trigger safety button(134) is pivotally mounted to the closure trigger (32) by pin (35). Thesafety button (134) is positioned between the firing trigger (130) andthe closure trigger (32) and has a pivot arm (136) protruding therefrom.See FIG. 4. When the closure trigger (32) is in the unactuated position,the safety button (134) is contained in the handle assembly (14) wherethe clinician cannot readily access it and move it between a safetyposition preventing actuation of the firing trigger (130) and a firingposition wherein the firing trigger (130) may be fired. As the cliniciandepresses the closure trigger (32), the safety button (134) and thefiring trigger (130) pivot downwardly to a position where they can thenbe manipulated by the clinician.

As indicated above, in at least one form, the longitudinally movabledrive member (120) has a rack of teeth (122) formed thereon for meshingengagement with a corresponding drive gear (86) of the gear reducerassembly (84). At least one form also includes a manually-actuatable“bailout” assembly (140) that is configured to enable the clinician tomanually retract the longitudinally movable drive member (120) shouldthe motor (82) become disabled. The bailout assembly (140) may include alever or bailout handle assembly (142) that is configured to be manuallypivoted into ratcheting engagement with a set of teeth (124) that arealso provided in the drive member (120). Thus, the clinician canmanually retract the drive member (120) by using the bailout handleassembly (142) to ratchet the drive member (120) in the proximaldirection “PD”. By way of example only, bailout assembly (140) may beconstructed and operable in accordance with at least some of theteachings of U.S. Pub. No. 2010/0089970, entitled “Powered SurgicalCutting and Stapling Apparatus with Manually Retractable Firing System,”published Apr. 15, 2010, the disclosure of which is incorporated byreference herein.

In addition to or in lieu of the foregoing, handle assembly (14) and/orother features of instrument (10) may be constructed and operable inaccordance with at least some of the teachings of U.S. patentapplication Ser. No. 14/226,142, entitled “Surgical InstrumentComprising a Sensor System,” filed Mar. 26, 2014, the disclosure ofwhich is incorporated by reference herein.

B. Exemplary Shaft Assembly

Turning now to FIGS. 1 and 6-11, the interchangeable shaft assembly(200) includes a surgical end effector (300) that comprises a lower jaw(1050) that is configured to operably support a staple cartridge (1070)therein. The end effector (300) may further include an anvil (1060) thatis pivotally supported relative to the lower jaw (1050). Theinterchangeable shaft assembly (200) may further include an articulationjoint (270) and an articulation lock (350) (FIG. 5) that can beconfigured to releasably hold the end effector (300) in a desiredposition relative to a shaft axis SA-SA. By way of example only, endeffector (300), articulation joint (270), and/or articulation lock (350)may be constructed and operable in accordance with at least some of theteachings of U.S. patent application Ser. No. 13/803,086, entitled“Articulatable Surgical Instrument Comprising an Articulation Lock,”filed Mar. 14, 2013, the disclosure of which is incorporated byreference herein. As another merely illustrative example, articulationjoint (270) and features that drive articulation joint may beconstructed and operable in accordance with at least some of theteachings of U.S. Pub. No. 2014/0243801, entitled “Surgical InstrumentEnd Effector Articulation Drive with Pinion and Opposing Racks,”published Aug. 28, 2014, the disclosure of which is incorporated byreference herein.

As can be seen in FIGS. 1-3 and 5, the interchangeable shaft assembly(200) can further include a proximal housing or nozzle (201) comprisedof nozzle portions (202) and (203). The interchangeable shaft assembly(200) can further include a closure tube (260) that can be utilized toclose and/or open the anvil (1060) of the end effector (300). Primarilyreferring now to FIG. 5, the shaft assembly (200) can include a spine(210) that can be configured to fixably support a shaft frame portion(212) of the articulation lock 350. The spine (210) can be configured toslidably support a firing member (220) therein; and also slidablysupport the closure tube (260) that extends around the spine (210). Thespine (210) can also be configured to slidably support a proximalarticulation driver (230). The articulation driver (230) has a distalend (231) that is configured to operably engage the articulation lock(350). The articulation lock (350) interfaces with an articulation frame(352) that is adapted to operably engage a drive pin (not shown) on theend effector frame (not shown). As indicated above, the articulationlock (350) and the articulation frame may be constructed and operable inaccordance with at least some of the teachings of U.S. PatentApplication Publication No. 2014/0263541, entitled “ArticulatableSurgical Instrument Comprising an Articulation Lock,” published Sep. 18,2014, the disclosure of which is incorporated by reference herein. Invarious circumstances, the spine (210) can comprise a proximal end (211)that is rotatably supported in a chassis (240). In one arrangement, forexample, the proximal end (211) of the spine (210) has a thread (214)formed thereon for threaded attachment to a spine bearing (not shown)configured to be supported within the chassis (240). Such an arrangementfacilitates rotatable attachment of the spine (210) to the chassis (240)such that the spine (210) may be selectively rotated about a shaft axisSA-SA relative to the chassis (240).

Referring primarily to FIG. 3-5, the interchangeable shaft assembly(200) further includes a closure shuttle (250) that is slidablysupported within the chassis (240) such that it may be axially movedrelative thereto. As can be seen in FIG. 3, the closure shuttle (250)includes a pair of proximally-protruding hooks (252) that are configuredfor attachment to the attachment pin (37) that is attached to the secondclosure link (38) as will be discussed in further detail below. Aproximal end (261) of the closure tube (260) is coupled to the closureshuttle (250) for relative rotation thereto. For example, a U shapedconnector (not shown) is inserted into an annular slot (262) in theproximal end (261) of the closure tube (260) and is retained withinvertical slots (not shown) in the closure shuttle (250). Such anarrangement serves to attach the closure tube (260) to the closureshuttle (250) for axial travel therewith while enabling the closure tube(260) to rotate relative to the closure shuttle (250) about the shaftaxis SA-SA. A closure spring is journaled on the closure tube (260) andserves to bias the closure tube (260) in the proximal direction “PD,”which can serve to pivot the closure trigger into the unactuatedposition when the shaft assembly is operably coupled to the handleassembly (14).

As noted above, the interchangeable shaft assembly (200) may furtherinclude an articulation joint (270). Other interchangeable shaftassemblies, however, may not be capable of articulation. In the presentexample, articulation joint (270) enables longitudinal motion to becommunicated from closure tube (260) to end effector (300) even whenarticulation joint (270) is in an articulated state. In particular, asshown in FIGS. 5-6, an end effector closure ring (1036) includes ahorseshoe aperture (275) and a tab (276) for engaging an opening tab onthe anvil (1060) in the various manners described in U.S. PatentApplication Publication No. 2014/0263541, which has been incorporated byreference herein. As described in further detail therein, the horseshoeaperture (275) and tab (276) engage a tab on the anvil (1060) when theanvil (1060) is opened. An upper double pivot link (277) includesupwardly projecting distal and proximal pivot pins that engagerespectively an upper distal pin hole in the upper proximally projectingtang (not shown) and an upper proximal pin hole in an upper distallyprojecting tang (264) on the closure tube (260). A lower double pivotlink (278) includes upwardly projecting distal and proximal pivot pinsthat engage respectively a lower distal pin hole in the lower proximallyprojecting tang (274) and a lower proximal pin hole in the lowerdistally projecting tang (265).

In use, the closure tube (260) is translated distally to close the anvil(1060), for example, in response to the actuation of the closure trigger(32). The anvil (1060) is closed by distally translating the closuretube (260) and thus the shaft closure sleeve assembly (272), causing itto strike a proximal surface on the anvil (1060) in the manner describedin the aforementioned reference U.S. Patent Application Publication No.2014/0263541. As was also described in detail in that reference, theanvil (1060) is opened by proximally translating the closure tube (260)and the shaft closure sleeve assembly (272), causing tab (276) and thehorseshoe aperture (275) to contact and push against the anvil tab tolift the anvil (1060). In the anvil-open position, the shaft closuretube (260) is moved to its proximal position. It should be understoodthat the configurations of tangs (264, 265) and links (277, 278) allowlongitudinal motion to be communicated from closure tube (260) toclosure ring (1036) regardless of whether articulation joint (270) is ina straight or articulated state.

As indicated above, the surgical instrument (10) may further include anarticulation lock (350) (FIG. 5) of the types and construction describedin further detail in U.S. Patent Application Publication No.2014/0263541, which can be configured and operated to selectively lockthe end effector (300) in a straight position or in any selectedarticulated position. Such arrangement enables the end effector (300) tobe rotated, or articulated, relative to the shaft closure tube (260)when the articulation lock (350) is in its unlocked state. In such anunlocked state, the end effector (300) can be positioned and pushedagainst soft tissue and/or bone, for example, surrounding the surgicalsite within the patient in order to cause the end effector (300) toarticulate relative to the closure tube (260). The end effector (300)may also be articulated relative to the closure tube (260) by anarticulation driver (230) (FIG. 5).

Still referring to FIG. 5, the interchangeable shaft assembly (200)further includes a firing member (220) that is supported for axialtravel within the shaft spine (210). The firing member (220) includes anintermediate firing shaft portion (222) that is configured forattachment to a distal cutting portion or firing beam (1082). The firingmember (220) may also be referred to herein as a “second shaft” and/or a“second shaft assembly”. As can be seen in FIG. 5, the intermediatefiring shaft portion (222) may include a longitudinal slot (223) in thedistal end thereof that can be configured to receive a tab (284) on theproximal end (282) of the distal firing beam (1082). The longitudinalslot (223) and the proximal end (282) can be sized and configured topermit relative movement therebetween and can comprise a slip joint(286). The slip joint (286) can permit the intermediate firing shaftportion (222) of the firing drive (220) to be moved to articulate theend effector (300) without moving, or at least substantially moving, thefiring beam (1082). Once the end effector (300) has been suitablyoriented, the intermediate firing shaft portion (222) can be advanceddistally until a proximal sidewall of the longitudinal slot (223) comesinto contact with the tab (284) in order to advance the firing beam(1082) and fire the staple cartridge positioned within the lower jaw(1050) (FIGS. 10A-10B). As can be further seen in FIG. 5, the shaftspine (210) has an elongate opening or window (213) therein tofacilitate assembly and insertion of the intermediate firing shaftportion (222) into the shaft frame (210). Once the intermediate firingshaft portion (222) has been inserted therein, a top frame segment (215)may be engaged with the shaft frame (212) to enclose the intermediatefiring shaft portion (222) and firing beam (1082) therein. The firingmember (220) may be further constructed and operable in accordance withat least some of the teachings of U.S. Patent Application PublicationNo. 2014/0263541.

Further to the above, the shaft assembly (200) can include a clutchassembly (400) that can be configured to selectively and releasablycouple the articulation driver (230) to the firing member (220). In oneform, the clutch assembly (400) includes a lock collar, or sleeve (402),positioned around the firing member (220). The lock sleeve (402) can berotated between an engaged position, in which the lock sleeve (402)couples the articulation driver (360) to the firing member (220); and adisengaged position, in which the articulation driver (360) is notoperably coupled to the firing member (200). When lock sleeve (402) isin its engaged position, distal movement of the firing member (220) canmove the articulation driver (360) distally; and, correspondingly,proximal movement of the firing member (220) can move the articulationdriver (230) proximally. When lock sleeve (402) is in its disengagedposition, movement of the firing member (220) is not transmitted to thearticulation driver (230); and, as a result, the firing member (220) canmove independently of the articulation driver (230). In variouscircumstances, the articulation driver (230) can be held in position bythe articulation lock (350) when the articulation driver (230) is notbeing moved in the proximal or distal directions by the firing member(220).

The lock sleeve (402) can comprise a cylindrical, or an at leastsubstantially cylindrical, body including a longitudinal aperture (notshown) defined therein configured to receive the firing member (220).The lock sleeve (402) can comprise diametrically-opposed,inwardly-facing lock protrusions (404) and an outwardly-facing lockmember (406). The lock protrusions (404) can be configured to beselectively engaged with the firing member (220). More particularly,when the lock sleeve (402) is in its engaged position, the lockprotrusions (404) are positioned within a drive notch (224) defined inthe firing member (220) such that a distal pushing force and/or aproximal pulling force can be transmitted from the firing member (220)to the lock sleeve (402). When the lock sleeve (402) is in its engagedposition, the second lock member (406) is received within a drive notch(232) defined in the articulation driver (230) such that the distalpushing force and/or the proximal pulling force applied to the locksleeve (402) can be transmitted to the articulation driver (230). Ineffect, the firing member (220), the lock sleeve (402), and thearticulation driver (230) will move together when the lock sleeve (402)is in its engaged position. On the other hand, when the lock sleeve(402) is in its disengaged position, the lock protrusions (404) may notbe positioned within the drive notch (224) of the firing member (220);and, as a result, a distal pushing force and/or a proximal pulling forcemay not be transmitted from the firing member (220) to the lock sleeve(402). Correspondingly, the distal pushing force and/or the proximalpulling force may not be transmitted to the articulation driver (230).In such circumstances, the firing member (220) can be slid proximallyand/or distally relative to the lock sleeve (402) and the proximalarticulation driver (230).

In one example, still referring to FIG. 5, the shaft assembly (200)further includes a switch drum (500) that is rotatably received on theclosure tube (260). The switch drum (500) comprises a hollow shaftsegment (not shown) that has a shaft boss (504) formed thereon forreceive an outwardly protruding actuation pin (410) therein. In variouscircumstances, the actuation pin (410) extends through a slot (267) intoa longitudinal slot (408) provided in the lock sleeve (402) tofacilitate axial movement of the lock sleeve (402) when it is engagedwith the articulation driver (230). A rotary torsion spring (420) isconfigured to engage the boss (504) on the switch drum (500) and aportion of the nozzle housing (203) to apply a biasing force to theswitch drum (500). The switch drum (500) can further comprise at leastpartially circumferential openings (506) defined therein that can beconfigured to receive circumferential mounts (not shown) extending fromthe nozzle halves (202, 203) and permit relative rotation, but nottranslation, between the switch drum (500) and the proximal nozzle(201). The mounts (not shown) also extend through openings (not shown)in the closure tube (260) to be seated in recesses (211) in the shaftspine (210). However, rotation of the nozzle (201) to a point where themounts reach the end of their respective slots (506) in the switch drum(500) will result in rotation of the switch drum (500) about the shaftaxis SA-SA. Rotation of the switch drum (500) will ultimately result inthe rotation of the actuation pin (410) and the lock sleeve (402)between its engaged and disengaged positions. Thus, in essence, thenozzle (201) may be employed to operably engage and disengage thearticulation drive system with the firing drive system in the variousmanners described in further detail in U.S. Patent ApplicationPublication No. 2014/0263541.

As also shown in FIG. 5, the shaft assembly (200) can comprise a slipring assembly (600) that can be configured to conduct electrical powerto and/or from the end effector (300) and/or communicate signals toand/or from the end effector (300), for example. The slip ring assembly(600) can comprise a proximal connector flange (604) mounted to achassis flange (not shown) extending from the chassis (not shown) and adistal connector flange (601) positioned within a slot defined in thenozzle housings (202, 203). The proximal connector flange (604) cancomprise a first face and the distal connector flange (601) can comprisea second face that is positioned adjacent to and movable relative to thefirst face. The distal connector flange (601) can rotate relative to theproximal connector flange (604) about the shaft axis SA-SA. The proximalconnector flange (604) can comprise a plurality of concentric, or atleast substantially concentric, conductors (602) defined in the firstface thereof. A connector (607) can be mounted on the proximal side ofthe connector flange (601) and may have a plurality of contacts (notshown). Each contact of the connector flange (601) corresponds to and isin electrical contact with one of the conductors (602). Such anarrangement permits relative rotation between the proximal connectorflange (604) and the distal connector flange (601) while maintainingelectrical continuity therebetween. The proximal connector flange (604)can include an electrical connector (606) that can place the conductors(602) in signal communication with a shaft circuit board (not shown)that is mounted to the shaft chassis (240), for example. In at least oneinstance, a wiring harness comprising a plurality of conductors canextend between the electrical connector (606) and the shaft circuitboard. The electrical connector (606) may extend proximally through aconnector opening defined in the chassis mounting flange. U.S. PatentApplication Publication No. 2014/0263552, entitled “Staple CartridgeTissue Thickness Sensor System,” published Sep. 18, 2014, and U.S.Patent Application Publication No. 2014/0263551, entitled “StapleCartridge Tissue Thickness Sensor System,” published Sep. 18, 2014 areincorporated herein by reference in their entireties. Further detailsregarding slip ring assembly (600) may be found in the aforementionedU.S. Patent Application Publication No. 2014/0263541.

As discussed above, the shaft assembly (200) can include a proximalportion that is fixably mounted to the handle assembly (14) and a distalportion that is rotatable about a longitudinal axis. The rotatabledistal shaft portion can be rotated relative to the proximal portionabout the slip ring assembly (600), as discussed above. The distalconnector flange (601) of the slip ring assembly (600) can be positionedwithin the rotatable distal shaft portion. Moreover, further to theabove, the switch drum (500) can also be positioned within the rotatabledistal shaft portion. When the rotatable distal shaft portion isrotated, the distal connector flange (601) and the switch drum (500) canbe rotated synchronously with one another. In addition, the switch drum(500) can be rotated between a first position and a second positionrelative to the distal connector flange (601). When the switch drum(500) is in its first position, the articulation drive system may beoperably disengaged from the firing drive system and, thus, theoperation of the firing drive system may not articulate the end effector(300) of the shaft assembly (200). When the switch drum (500) is in itssecond position, the articulation drive system may be operably engagedwith the firing drive system and, thus, the operation of the firingdrive system may articulate the end effector (300) of the shaft assembly(200). When the switch drum (500) is moved between its first positionand its second position, the switch drum (500) is moved relative todistal connector flange (601). In various instances, the shaft assembly(200) can comprise at least one sensor configured to detect the positionof the switch drum (500). For example, the distal connector flange (601)can comprise a Hall Effect sensor (not shown), for example, and theswitch drum (500) can comprise a magnetic element, such as permanentmagnet (not shown) for example. The Hall Effect sensor can be configuredto detect the position of the permanent magnet. When the switch drum(500) is rotated between its first position and its second position, thepermanent magnet can move relative to the Hall Effect sensor. In variousinstances, Hall Effect sensor can detect changes in a magnetic fieldcreated when the permanent magnet (505) is moved. The Hall Effect sensorcan be in signal communication with the shaft circuit board and/or thehandle circuit board (100), for example. Based on the signal from theHall Effect sensor, a microcontroller on the shaft circuit board and/orthe handle circuit board (100) can determine whether the articulationdrive system is engaged with or disengaged from the firing drive system.

Referring again to FIGS. 2 and 3A-B, the handle assembly (14) includesan electrical connector (4000) comprising a plurality of electricalcontacts (4001 a-f). In particular, the electrical connector (4000) ofthe present example comprises a first contact (4001 a), a second contact(4001 b), a third contact (4001 c), a fourth contact (4001 d), a fifthcontact (4001 e), and a sixth contact (4001 f). Electrical contacts(4001 a-f) are configured and arranged to contact complementary contacts(4011 a-f) at the proximal end of shaft assembly (200) when shaftassembly (200) is coupled with handle assembly (14), such that contacts(4001 a-f, 4011 a-f) provide paths for electrical communication betweenhandle assembly (14) and shaft assembly (200). Exemplary details of suchelectrical communication are described elsewhere herein. While theillustrated example utilizes six contacts, other embodiments areenvisioned which may utilize more or less than six contacts. Asillustrated in FIG. 3B, the first contact (4001 a) is in electricalcommunication with a transistor (4008), contacts (4001 b-e) each are inelectrical communication with a microcontroller (7004), and the sixthcontact (4001 f) is in electrical communication with a ground. Incertain circumstances, one or more of the electrical contacts (4001 b-e)may be in electrical communication with one or more output channels ofthe microcontroller (7004) and can be energized, or have a voltagepotential applied thereto, when the handle assembly (14) is in a poweredstate.

In addition or in the alternative, one or more of the electricalcontacts (4001 b-e) may be in electrical communication with one or moreinput channels of the microcontroller (7004) and, when the handleassembly (14) is in a powered state, the microcontroller (7004) can beconfigured to detect when a voltage potential is applied to suchelectrical contacts (4001 b-e). When shaft assembly (200) is not coupledwith the handle assembly (14), electrical contacts (4001 a-f) may beexposed and may be prone to being accidentally placed in electricalcommunication with one another. Such circumstances may arise when one ormore of the contacts (4001 a-f) come into contact with an electricallyconductive material. When this occurs, the microcontroller (7004) mayreceive an erroneous input and/or the shaft assembly (200) can receivean erroneous output, for example. To address this issue, in variouscircumstances, the handle assembly (14) may be configured to remain in apowered-down state when the handle assembly (14) is not coupled to ashaft assembly, such as shaft assembly (200). In such circumstances, themicrocontroller (7004) may be configured to ignore inputs, or voltagepotentials, applied to the contacts (4001 a-f) in electricalcommunication with the microcontroller (7004) until shaft assembly (14)is attached to the handle assembly (14). Even though the microcontroller(7004) may be supplied with power to operate other functionalities ofthe handle assembly (14) in such circumstances, the handle assembly (14)may be in a powered-down state. In a way, the electrical connector(4000) may be in a powered-down state as voltage potentials applied tothe electrical contacts (4001 b-4001 e) may not affect the operation ofthe handle assembly (14). It will be appreciated that electricalcontacts (4001 a) and (4001 f), which are not in electricalcommunication with the microcontroller (7004) in the example shown, mayor may not be in a powered-down state regardless of the state of thecontacts (4001 b-e). For instance, in one example, sixth contact (4001f) may remain in electrical communication with a ground regardless ofwhether the handle assembly (14) is in a powered-up or a powered-downstate.

Furthermore, the transistor (4008), and/or any other suitablearrangement of transistors, such as transistor (4010), for example,and/or switches may be configured to control the supply of power from apower source (4004) (e.g., power pack (92)) to the first electricalcontact (4001 a), regardless of whether the handle assembly (14) is in apowered-up or a powered-down state. In various circumstances, the shaftassembly (200) can be configured to change the state of the transistor(4008) when the shaft assembly (200) is engaged with the handle assembly(14). In certain circumstances, further to the below, a Hall Effectsensor (4002) can be configured to switch the state of transistor (4010)which, as a result, can switch the state of transistor (4008) andultimately supply power from power source (4004) to first contact (4001a). In this way, both the power circuits and the signal circuits to theconnector (4000) can be powered down when shaft assembly (200) is notcoupled to the handle assembly (14), and powered up when shaft assembly(200) is installed to the handle 14.

In various examples, referring again to FIG. 3B, the handle assembly(14) includes the Hall Effect sensor (4002), which can be configured todetect a detectable element, such as a magnetic element (4007) (FIG. 3)on shaft assembly (200) when the shaft assembly (200) is coupled to thehandle assembly (14). The Hall Effect sensor (4002) is in communicationwith a power source (4006) (e.g., power pack (92)), which is configuredto amplify the detection signal of the Hall Effect sensor (4002) andcommunicate with an input channel of the microcontroller (7004) via thecircuit illustrated in FIG. 3B. Once the microcontroller (7004) has areceived an input indicating that shaft assembly (200) has been at leastpartially coupled to the handle (14) such that electrical contacts (4001a-f) are no longer exposed, the microcontroller (7004) can enter intoits normal, or powered-up, operating state. In such an operating state,the microcontroller (7004) will evaluate the signals transmitted to oneor more of the contacts (4001 b-e) from the shaft assembly and/ortransmit signals to the shaft assembly (200) through one or more of thecontacts (4001 b-e) in normal use thereof. In various circumstances, theshaft assembly (200) may have to be fully seated before the Hall Effectsensor (4002) can detect the magnetic element (4007). While a HallEffect sensor (4002) is utilized to detect the presence of the shaftassembly (200) in the present example, it should be understood that anyother suitable system of sensors and/or switches can be utilized todetect whether shaft assembly (200) has been coupled to the handleassembly (14), such as those described below. In addition to or in lieuof the foregoing, shaft assembly (200) and/or other features ofinstrument (10) may be constructed and operable in accordance with atleast some of the teachings of U.S. patent application Ser. No.14/226,142, entitled “Surgical Instrument Comprising a Sensor System,”filed Mar. 26, 2014, the disclosure of which is incorporated byreference herein.

C. Exemplary End Effector

As shown in FIGS. 6-11, end effector (300) of the present exampleincludes a lower jaw (1050) and a pivotable anvil (1060). Anvil (1060)includes a pair of integral, outwardly extending pins (1066) that aredisposed in corresponding curved slots (1054) of lower jaw (1050). Anvil(1060) is pivotable toward and away from lower jaw (1050) between anopen position (shown in FIG. 7) and a closed position (shown in FIGS. 6,10A-10B). Use of the term “pivotable” (and similar terms with “pivot” asa base) should not be read as necessarily requiring pivotal movementabout a fixed axis. For instance, in the present example, anvil (1060)pivots about an axis that is defined by pins (1066), which slide alongcurved slots (1054) of lower jaw (1050) as anvil (1060) moves towardlower jaw (1050). In such versions, the pivot axis translates along thepath defined by slots (1054) while anvil (1060) simultaneously pivotsabout that axis. In addition or in the alternative, the pivot axis mayslide along slots (1054) first, with anvil (1060) then pivoting aboutthe pivot axis after the pivot axis has slid a certain distance alongthe slots (1054). It should be understood that such sliding/translatingpivotal movement is encompassed within terms such as “pivot,” “pivots,”“pivotal,” “pivotable,” “pivoting,” and the like. Of course, someversions may provide pivotal movement of anvil (1060) about an axis thatremains fixed and does not translate within a slot or channel, etc.

As best seen in FIG. 8, lower jaw (1050) of the present example definesa channel (1052) that is configured to receive a staple cartridge(1070). Staple cartridge (1070) may be inserted into channel (1052), endeffector (300) may be actuated, and then staple cartridge (1070) may beremoved and replaced with another staple cartridge (1070). Lower jaw(1050) thus releasably retains staple cartridge (1070) in alignment withanvil (1060) for actuation of end effector (300). In some versions,lower jaw (1050) is constructed in accordance with at least some of theteachings of U.S. Patent Application Publication No. 2014/0329044,entitled “Installation Features for Surgical Instrument End EffectorCartridge,” published Aug. 28, 2014, the disclosure of which isincorporated by reference herein. Other suitable forms that lower jaw(1050) may take will be apparent to those of ordinary skill in the artin view of the teachings herein.

As best seen in FIGS. 7-9, staple cartridge (1070) of the presentexample comprises a cartridge body (1071) and a tray (1076) secured tothe underside of cartridge body (1071). The upper side of cartridge body(1071) presents a deck (1073), against which tissue may be compressedwhen anvil (1060) is driven to a closed position by distal advancementof closure tube (260) and closure ring (1036). Cartridge body (1071)further defines a longitudinally extending channel (1072) and aplurality of staple pockets (1074). A staple (1077) is positioned ineach staple pocket (1074). A staple driver (1075) is also positioned ineach staple pocket (1074), underneath a corresponding staple (1077), andabove tray (1076). As will be described in greater detail below, stapledrivers (1075) are operable to translate upwardly in staple pockets(1074) to thereby drive staples (1077) upwardly through staple pockets(1074) and into engagement with anvil (1060). Staple drivers (1075) aredriven upwardly by a wedge sled (1078), which is captured betweencartridge body (1071) and tray (1076), and which translateslongitudinally through cartridge body (1071) in response to distaladvancement of knife member (1080). Wedge sled (1078) includes a pair ofobliquely angled cam surfaces (1079), which are configured to engagestaple drivers (1075) and thereby drive staple drivers (1075) upwardlyas wedge sled (1078) translates longitudinally through cartridge (1070).For instance, when wedge sled (1078) is in a proximal position as shownin FIG. 10A, staple drivers (1075) are in downward positions and staples(1077) are located in staple pockets (1074). As wedge sled (1078) isdriven to the distal position shown in FIG. 10B by distally translatingknife member (1080), wedge sled (1078) drives staple drivers (1075)upwardly, thereby driving staples (1077) out of staple pockets (1074)and into staple forming pockets (1064). Thus, staple drivers (1075)translate along a vertical dimension as wedge sled (1078) translatesalong a horizontal dimension.

It should be understood that the configuration of staple cartridge(1070) may be varied in numerous ways. For instance, staple cartridge(1070) of the present example includes two longitudinally extending rowsof staple pockets (1074) on one side of channel (1072); and another setof two longitudinally extending rows of staple pockets (1074) on theother side of channel (1072). However, in some other versions, staplecartridge (1070) includes three, one, or some other number of staplepockets (1074) on each side of channel (1072). In some versions, staplecartridge (1070) is constructed and operable in accordance with at leastsome of the teachings of U.S. Patent Application Publication No.2014/0239042, entitled “Integrated Tissue Positioning and Jaw AlignmentFeatures for Surgical Stapler,” published Aug. 28, 2014, the disclosureof which is incorporated by reference herein. In addition or in thealternative, staple cartridge (1070) may be constructed and operable inaccordance with at least some of the teachings of U.S. PatentApplication Publication No. 2014/0239044, entitled “InstallationFeatures for Surgical Instrument End Effector Cartridge,” published Aug.28, 2014, the disclosure of which is incorporated by reference herein.Other suitable forms that staple cartridge (1070) may take will beapparent to those of ordinary skill in the art in view of the teachingsherein.

As best seen in FIG. 7, anvil (1060) of the present example comprises alongitudinally extending channel (1062) and a plurality of stapleforming pockets (1064). Channel (1062) is configured to align withchannel (1072) of staple cartridge (1070) when anvil (1060) is in aclosed position. Each staple forming pocket (64) is positioned to lieover a corresponding staple pocket (1074) of staple cartridge (1070)when anvil (1060) is in a closed position. Staple forming pockets (1064)are configured to deform the legs of staples (1077) when staples (1077)are driven through tissue and into anvil (1060). In particular, stapleforming pockets (1064) are configured to bend the legs of staples (1077)to secure the formed staples (1077) in the tissue. Anvil (1060) may beconstructed in accordance with at least some of the teachings of U.S.Patent Application Publication No. 2014/0239042, entitled “IntegratedTissue Positioning and Jaw Alignment Features for Surgical Stapler,”published Aug. 28, 2014; at least some of the teachings of U.S. PatentApplication Publication No. 2014/0239036, entitled “Jaw Closure Featurefor End Effector of Surgical Instrument,” published Aug. 28, 2014;and/or at least some of the teachings of U.S. Patent ApplicationPublication No. 2014/0239037, entitled “Staple Forming Features forSurgical Stapling Instrument,” published Aug. 28, 2014, the disclosureof which is incorporated by reference herein. Other suitable forms thatanvil (1060) may take will be apparent to those of ordinary skill in theart in view of the teachings herein.

In the present example, knife member (1080) is configured to translatethrough end effector (300). As best seen in FIGS. 8 and 10A-10B, knifemember (1080) is secured to the distal end of a firing beam (1082),which extends through a portion of shaft assembly (200). As best seen inFIGS. 7 and 9, knife member (1080) is positioned in channels (1062,1072) of anvil (1060) and staple cartridge (1070). Knife member (1080)includes a distally presented cutting edge (1084) that is configured tosever tissue that is compressed between anvil (1060) and deck (1073) ofstaple cartridge (1070) as knife member (1080) translates distallythrough end effector (300). As noted above and as shown in FIGS.10A-10B, knife member (1080) also drives wedge sled (1078) distally asknife member (1080) translates distally through end effector (300),thereby driving staples (1077) through tissue and against anvil (1060)into formation. In some versions, end effector (300) includes lockoutfeatures that are configured to prevent knife member (1080) fromadvancing distally through end effector (300) when a staple cartridge(1070) is not inserted in lower jaw (1050). In addition or in thealternative, end effector (300) may include lockout features that areconfigured to prevent knife member (1080) from advancing distallythrough end effector (300) when a staple cartridge (1070) that hasalready been actuated once (e.g., with all staples (1077) deployedtherefrom) is inserted in lower jaw (1050). By way of example only, suchlockout features may be configured in accordance with at least some ofthe teachings of U.S. Patent Application Publication No. 2014/0239041,entitled “Lockout Feature for Movable Cutting Member of SurgicalInstrument,” published Aug. 28, 2014, the disclosure of which isincorporated by reference herein; and/or at least some of the teachingsof U.S. patent application Ser. No. 14/314,108, entitled “Method ofUsing Lockout Features for Surgical Stapler Cartridge,” filed on Jun.25, 2014, the disclosure of which is incorporated by reference herein.Other suitable forms that lockout features may take will be apparent tothose of ordinary skill in the art in view of the teachings herein.Alternatively, end effector (300) may simply omit such lockout features.

In the present example, anvil (1060) is driven toward lower jaw (1050)by advancing closure ring (1036) distally relative to end effector(300). Closure ring (1036) cooperates with anvil (1060) through acamming action to drive anvil (1060) toward lower jaw (1050) in responseto distal translation of closure ring (1036) relative to end effector(300). Similarly, closure ring (1036) may cooperate with anvil (1060) toopen anvil (1060) away from lower jaw (1050) in response to proximaltranslation of closure ring (1036) relative to end effector (300). Byway of example only, closure ring (1036) and anvil (1060) may interactin accordance with at least some of the teachings of U.S. PatentApplication Publication No. 2014/0239036, entitled “Jaw Closure Featurefor End Effector of Surgical Instrument,” published Aug. 28, 2014, thedisclosure of which is incorporated by reference herein; and/or inaccordance with at least some of the teachings of U.S. patentapplication Ser. No. 14/314,164 entitled “Jaw Opening Feature forSurgical Stapler,” filed on Jun. 25, 2014, the disclosure of which isincorporated by reference herein. As noted above, handle assembly (14)includes a pistol grip (19) and a closure trigger (32). As also notedabove, anvil (1060) is closed toward lower jaw (1050) in response todistal advancement of closure ring (1036). In the present example,closure trigger (32) is pivotable toward pistol grip (19) to driveclosure tube (260) and closure ring (1036) distally. Various suitablecomponents that may be used to convert pivotal movement of closuretrigger (32) toward pistol grip (19) into distal translation of closuretube (260) and closure ring (1036) relative to handle assembly (14) aredescribed in detail above. Similarly, other suitable features that maybe used to actuate anvil (1060) will be apparent to those of ordinaryskill in the art in view of the teachings herein.

FIG. 11 shows end effector (300) having been actuated through a singlestroke through tissue (1090). As shown, cutting edge (1084) (obscured inFIG. 11) has cut through tissue (1090), while staple drivers (1075) havedriven two alternating rows of staples (1077) through the tissue (1090)on each side of the cut line produced by cutting edge (1084). Staples(1077) are all oriented substantially parallel to the cut line in thisexample, though it should be understood that staples (1077) may bepositioned at any suitable orientations. In the present example, endeffector (300) is withdrawn from the trocar after the first stroke iscomplete, the spent staple cartridge (1070) is replaced with a newstaple cartridge (1070), and end effector (300) is then again insertedthrough the trocar to reach the stapling site for further cutting andstapling. This process may be repeated until the desired amount of cutsand staples (1077) have been provided. Anvil (1060) may need to beclosed to facilitate insertion and withdrawal through the trocar; andanvil (1060) may need to be opened to facilitate replacement of staplecartridge (1070).

It should be understood that cutting edge (1084) may sever tissuesubstantially contemporaneously with staples (1077) being driven throughtissue during each actuation stroke. In the present example, cuttingedge (1084) just slightly lags behind driving of staples (1077), suchthat a staple (1077) is driven through the tissue just before cuttingedge (1084) passes through the same region of tissue, though it shouldbe understood that this order may be reversed or that cutting edge(1084) may be directly synchronized with adjacent staples. While FIG. 11shows end effector (300) being actuated in two layers (1092, 1094) oftissue (1090), it should be understood that end effector (300) may beactuated through a single layer of tissue (1090) or more than two layers(1092, 1094) of tissue. It should also be understood that the formationand positioning of staples (1077) adjacent to the cut line produced bycutting edge (1084) may substantially seal the tissue at the cut line,thereby reducing or preventing bleeding and/or leaking of other bodilyfluids at the cut line. Furthermore, while FIG. 11 shows end effector(300) being actuated in two substantially flat, apposed planar layers(1092, 1094) of tissue, it should be understood that end effector (300)may also be actuated across a tubular structure such as a blood vessel,a section of the gastrointestinal tract, etc. FIG. 11 should thereforenot be viewed as demonstrating any limitation on the contemplated usesfor end effector (300). Various suitable settings and procedures inwhich instrument (10) may be used will be apparent to those of ordinaryskill in the art in view of the teachings herein.

It should also be understood that any other components or features ofinstrument (10) may be configured and operable in accordance with any ofthe various references cited herein. Additional exemplary modificationsthat may be provided for instrument (10) will be described in greaterdetail below. Various suitable ways in which the below teachings may beincorporated into instrument (10) will be apparent to those of ordinaryskill in the art. Similarly, various suitable ways in which the belowteachings may be combined with various teachings of the references citedherein will be apparent to those of ordinary skill in the art. It shouldalso be understood that the below teachings are not limited toinstrument (10) or devices taught in the references cited herein. Thebelow teachings may be readily applied to various other kinds ofinstruments, including instruments that would not be classified assurgical staplers. Various other suitable devices and settings in whichthe below teachings may be applied will be apparent to those of ordinaryskill in the art in view of the teachings herein.

II. Exemplary Electrical Circuits and Components for Surgical Instrument

A. Exemplary Control Circuit and Components

FIGS. 12-1 and 12-2 show an exemplary electrical circuit and componentarrangement that may be incorporated into a surgical instrument, such asinstrument (10). By way of example only, at least a portion of thecircuit shown in FIGS. 12-1 and 12-2 may be incorporated into circuitboard (100) described above. As shown, the handle assembly (2002), whichmay be configured in accordance with handle assembly (200) for example,includes a motor (2014) that can be controlled by a motor driver (2015).Motor (2014) is configured to be employed by the firing system of thesurgical instrument (2000), such as the firing system described hereinwith respect to instrument (10). Motor (2014) may be further configuredand/or operable similar or identical to motor (82) described above. Incertain circumstances, the motor driver (2015) may comprise an H-BridgeFETs (2019), as illustrated in FIG. 12-2. The motor (2014) can bepowered by a power assembly (2006) (FIG. 13), which can be releasablymounted to the handle assembly (2002), power assembly (2006) beingconfigured to supply control power to the surgical instrument (2000).The power assembly (2006) may comprise a battery (2007) (FIG. 13) thatmay include a number of battery cells connected in series that can beused as the power source to power the surgical instrument (2000). Insuch a configuration, the power assembly (2006) may be referred to as abattery pack. Power assembly (2006) may be configured in accordance withpower source (90) described herein. In certain circumstances, thebattery cells of the power assembly (2006) may be replaceable and/orrechargeable. In at least one example, the battery cells can beLithium-Ion batteries that can be removably coupled to the powerassembly (2006).

Examples of drive systems and closure systems that are suitable for usewith the surgical instrument (2000) are disclosed in U.S. ProvisionalPatent Application Ser. No. 61/782,866, entitled “Control System of aSurgical Instrument,” and filed Mar. 14, 2013, the entire disclosure ofwhich is incorporated by reference herein in its entirety. For example,as with motor (82) described above, the electric motor (2014) of thisexample can include a rotatable shaft (not shown) that may operablyinterface with a gear reducer assembly that can be mounted in meshingengagement with a set, or rack, of drive teeth on alongitudinally-movable drive member. In use, a voltage polarity providedby the battery (2007) (FIG. 13) can operate the electric motor (2014) todrive the longitudinally-movable drive member to effectuate the endeffector (2008). For example, the motor (2014) can be configured todrive the longitudinally-movable drive member to advance a firingmechanism to fire staples into tissue captured by the end effector(2008) from a staple cartridge assembled with the end effector (2008)and/or advance a cutting member to cut tissue captured by the endeffector (2008), for example, in a similar manner described with respectto end effector (300).

In certain circumstances, the surgical instrument (2000) may comprise alockout mechanism to prevent a user from coupling incompatible handleassemblies and power assemblies. For example, the power assembly (2006)may include a mating element. In certain circumstances, the matingelement can be a tab extending from the power assembly (2006). Incertain instances, the handle assembly (2002) may comprise acorresponding mating element (not shown) for mating engagement with themating element. Such an arrangement can be useful in preventing a userfrom coupling incompatible handle assemblies and power assemblies.

Still referring to FIGS. 12-1 and 12-2, the shaft assembly (2004) mayinclude a shaft assembly controller (2022) that can communicate with thepower management controller (2016) through an interface (2024) while theshaft assembly (2004) and the power assembly (2006) are coupled to thehandle assembly (2002). For example, the interface (2024) may comprise afirst interface portion (2025) that may include one or more electricconnectors (2026) (e.g., electrical connectors 4001 a-f as shown inFIGS. 3A-3B) for coupling engagement with corresponding shaft assemblyelectric connectors (2028) (e.g., electrical connectors 4011 a-f asshown in FIG. 3A) and a second interface portion (2027) that may includeone or more electric connectors (2030) for coupling engagement withcorresponding power assembly electric connectors (2032) to permitelectrical communication between the shaft assembly controller (2022)and the power management controller (2016) while the shaft assembly(2004) and the power assembly (2006) are coupled to the handle assembly(2002). One or more communication signals can be transmitted through theinterface (2024) to communicate one or more of the power requirements ofthe attached interchangeable shaft assembly (2004) to the powermanagement controller (2016). In response, the power managementcontroller may modulate the power output of the battery (2007) of thepower assembly (2006), as described below in greater detail, inaccordance with the power requirements of the attached shaft assembly(2004). In certain circumstances, one or more of the electric connectors(2026, 2028, 2030, and/or 2032) may comprise switches that can beactivated after mechanical coupling engagement of the handle assembly(2002) to the shaft assembly (2004) and/or to the power assembly (2006)to allow electrical communication between the shaft assembly controller(2022) and the power management controller (2016).

In certain circumstances, the interface (2024) can facilitatetransmission of the one or more communication signals between the powermanagement controller (2016) and the shaft assembly controller (2022) byrouting such communication signals through a main controller (2017)residing in the handle assembly (2002), for example. In othercircumstances, the interface (2024) can facilitate a direct line ofcommunication between the power management controller (2016) and theshaft assembly controller (2022) through the handle assembly (2002)while the shaft assembly (2004) and the power assembly (2006) arecoupled to the handle assembly (2002).

In one instance, the main microcontroller (2017) may be any single coreor multicore processor such as those known under the trade name ARMCortex by Texas Instruments. In one instance, the surgical instrument(2000) may comprise a power management controller (2016) such as, forexample, a safety microcontroller platform comprising twomicrocontroller-based families such as TMS570 and RM4x known under thetrade name Hercules ARM Cortex R4, also by Texas Instruments.Nevertheless, other suitable substitutes for microcontrollers and safetyprocessor may be employed, without limitation. In one instance, thesafety processor (1004) may be configured specifically for IEC 61508 andISO 26262 safety critical applications, among others, to provideadvanced integrated safety features while delivering scalableperformance, connectivity, and memory options.

In certain instances, the microcontroller (2017) may be an LM 4F230H5QR,available from Texas Instruments, for example. In at least one example,the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle serial random accessmemory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available for the productdatasheet. The present disclosure should not be limited in this context.

B. Exemplary Power Output Management Circuit and Method

Referring now primarily to FIGS. 13 and 14, the power assembly (2006)may include a power management circuit (2034) that may comprise thepower management controller (2016), a power modulator (2038), and acurrent sense circuit (2036). The power management circuit (2034) can beconfigured to modulate power output of the battery (2007) based on thepower requirements of the shaft assembly (2004) while the shaft assembly(2004) and the power assembly (2006) are coupled to the handle assembly(2002). For example, the power management controller (2016) can beprogrammed to control the power modulator (2038) of the power output ofthe power assembly (2006) and the current sense circuit (2036) can beemployed to monitor power output of the power assembly (2006) to providefeedback to the power management controller (2016) about the poweroutput of the battery (2007) so that the power management controller(2016) may adjust the power output of the power assembly (2006) tomaintain a desired output, as illustrated in FIG. 14.

It is noteworthy that the power management controller (2016) and/or theshaft assembly controller (2022) each may comprise one or moreprocessors and/or memory units that may store a number of softwaremodules. Although certain modules and/or blocks of the surgicalinstrument (2000) may be described by way of example, it can beappreciated that a greater or lesser number of modules and/or blocks maybe used. Further, although various instances may be described in termsof modules and/or blocks to facilitate description, such modules and/orblocks may be implemented by one or more hardware components, e.g.,processors, Digital Signal Processors (DSPs), Programmable Logic Devices(PLDs), Application Specific Integrated Circuits (ASICs), circuits,registers and/or software components, e.g., programs, subroutines, logicand/or combinations of hardware and software components.

In certain instances, the surgical instrument (2000) may comprise anoutput device (2042) that may include one or more devices for providinga sensory feedback to a user. Such devices may comprise, for example,visual feedback devices (e.g., an LCD display screen, LED indicators),audio feedback devices (e.g., a speaker, a buzzer), and/or tactilefeedback devices (e.g., haptic actuators). In certain circumstances, theoutput device (2042) may comprise a display that may be included in thehandle assembly (2002). The shaft assembly controller (2022) and/or thepower management controller (2016) can provide feedback to a user of thesurgical instrument (2000) through the output device (2042). Theinterface (2024) can be configured to connect the shaft assemblycontroller (2022) and/or the power management controller (2016) to theoutput device (2042). Those of ordinary skill in the art will appreciatethat the output device (2042) can instead be integrated with the powerassembly (2006). In such circumstances, communication between the outputdevice (2042) and the shaft assembly controller (2022) may beaccomplished through the interface (2024) while the shaft assembly(2004) is coupled to the handle assembly (2002).

In certain instances, the microcontroller (2017) may be an LM 4F230H5QR,available from Texas Instruments, for example. In at least one example,the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle serial random accessmemory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available for the productdatasheet. The present disclosure should not be limited in this context.

Still referring to FIGS. 13 and 14, the power assembly (2006) mayinclude a power management circuit (2034) that may comprise the powermanagement controller (2016), a power modulator (2038), and a currentsense circuit (2036). The power management circuit (2034) can beconfigured to modulate power output of the battery (2007) based on thepower requirements of the shaft assembly (2004) (blocks 2039 a, 2039 b)while the shaft assembly (2004) and the power assembly (2006) arecoupled to the handle assembly (2002). For example, the power managementcontroller (2016) can be programmed to control the power modulator(2038) of the power output of the power assembly (2006). The currentsense circuit (2036) can be employed to monitor power output of thepower assembly (2006) to provide feedback to the power managementcontroller (2016) about the power output of the battery (2007) (block2039 c) so that the power management controller (2016) may adjust thepower output of the power assembly (2006) to maintain a desired output(block 2039 d).

C. Exemplary Charge State Circuit and Method

FIG. 15 shows another exemplary electrical circuit and componentarrangement that may be incorporated into instrument (10). By way ofexample only, at least a portion of the circuit shown in FIG. 15 may beincorporated into circuit board (100) described above. As shown, thearrangement includes a working assembly (2054) and a power assembly(2056). Working assembly (2054) of this example comprises a handleassembly (e.g., like handle assembly (14) described above, etc.) and ashaft assembly (e.g., like shaft assembly (200) described above, etc.)extending between the handle assembly and the end effector (2052) (whichmay comprise an end effector (300) as described above, etc.). In certaininstances, the surgical instrument (2050) may include a power assembly(2056) (e.g., similar to power source (90) described above, etc.) thatcan be employed with a plurality of interchangeable working assembliessuch as, for example, the interchangeable working assembly (2054). Suchinterchangeable working assemblies (2054) may include surgical endeffectors such as, for example, the end effector (2052) that can beconfigured to perform one or more surgical tasks or procedures, similarto the end effector (300) described herein. In certain circumstances,the handle assembly (2053) and the shaft (2055) may be integrated into asingle unit. In other circumstances, the handle assembly (2053) and theshaft (2055) may removably attached to each other. The power assembly(2056) may be provided as a variation of power source (90) describedabove.

Similar to the surgical instrument (2000), the surgical instrument(2050) may operably support a plurality of drive systems that can bepowered by the power assembly (2056) while the power assembly (2056) iscoupled to the interchangeable working assembly (2054). For example, theinterchangeable working assembly (2054) can operably support a closuredrive system, which may be employed to apply closing and opening motionsto the end effector (2052). In at least one example, the interchangeableworking assembly (2054) may operably support a firing drive system thatcan be configured to apply firing motions to the end effector (2052).Examples of drive systems suitable for use with the surgical instrument(2050) are described in U.S. Provisional Patent Application Ser. No.61/782,866, entitled “Control System of a Surgical Instrument,” andfiled Mar. 14, 2013, the entire disclosure of which is incorporated byreference herein in its entirety.

Referring to FIG. 15, the power assembly (2056) of the surgicalinstrument (2050) can be removably coupled to an interchangeable workingassembly such as, for example, the interchangeable working assembly(2054). Various coupling means can be utilized to releasably couple thepower assembly (2056) to the interchangeable working assembly (2054).Exemplary coupling mechanisms are described herein and are described inthe aforementioned U.S. Provisional Patent Application Ser. No.61/782,866. Still referring to FIG. 15, the power assembly (2056) mayinclude a power source (2058) such as, for example, a battery that canbe configured to power the interchangeable working assembly (2054) whilecoupled to the power assembly (2056). In certain instances, the powerassembly (2056) may include a memory (2060) that can be configured toreceive and store information about the battery (2058) and/or theinterchangeable working assembly (2054) such as, for example, the stateof charge of the battery (2058), the number of treatment cyclesperformed using the battery (2058), and/or identification informationfor the interchangeable working assemblies coupled to the power assembly(2056) during the life cycle of the battery (2058). Further to theabove, the interchangeable working assembly (2054) may include acontroller (2062) that can be configured to provide the memory (2060)with such information about the battery (2058) and/or theinterchangeable working assembly (2054).

Still referring to FIG. 15, the power assembly (2056) may include aninterface (2064) that can be configured to facilitate electricalcommunication between the memory (2060) of the power assembly (2056) anda controller of an interchangeable working assembly that is coupled tothe power assembly (2056) such as, for example, the controller (2062) ofthe interchangeable working assembly (2054). For example, the interface(2064) may comprise one or more connectors (2066) for couplingengagement with corresponding working assembly connectors (2068) topermit electrical communication between the controller (2062) and thememory (2060) while the interchangeable working assembly (2054) iscoupled to the power assembly (2056). In certain circumstances, one ormore of the electric connectors (2066) and/or (2068) may compriseswitches that can be activated after coupling engagement of theinterchangeable working assembly (2054) and the power assembly (2056) toallow electric communication between the controller (2062) and thememory (2060).

Still referring to FIG. 15, the power assembly (2056) may include astate of charge monitoring circuit (2070). In certain circumstances, thestate of charge monitoring circuit (2070) may comprise a coulombcounter. The controller (2062) can be in communication with the state ofcharge monitoring circuit (2070) while the interchangeable workingassembly (2054) is coupled to the power assembly (2056). The state ofcharge monitoring circuit (2070) can be operable to provide for accuratemonitoring of charge states of the battery (2058).

FIG. 16 shows a flowchart depicting an exemplary method of use of acontroller of an interchangeable working assembly such as, for example,the controller (2062) of the interchangeable working assembly (2054)while coupled to the power assembly (2056). For example, the controller(2062) may comprise one or more processors and/or memory units that maystore a number of software modules such as, for example, the module(2072). Although certain modules and/or blocks of the surgicalinstrument (2050) may be described by way of example, it can beappreciated that a greater or lesser number of modules and/or blocks maybe used. Further, although various instances may be described in termsof modules and/or blocks to facilitate description, such modules and/orblocks may be implemented by one or more hardware components, e.g.,processors, DSPs, PLDs, ASICs, circuits, registers and/or softwarecomponents, e.g., programs, subroutines, logic and/or combinations ofhardware and software components.

Upon coupling the interchangeable working assembly (2054) to the powerassembly (2056), the interface (2064) may facilitate communicationbetween the controller (2062) and the memory (2060) and/or the state ofcharge monitoring circuit (2070) to execute the module (2072), asillustrated in FIG. 16. For example, the controller (2062) of theinterchangeable working assembly (2054) may utilize the state of chargemonitoring circuit (2070) to measure the state of charge of the battery(2058) (block 2072 a). The controller (2062) may then access the memory(2060) and determine whether a previous value for the state of charge ofthe battery (2058) is stored in the memory (2060) (block 2072 b). When aprevious value is detected, the controller (2060) may compare themeasured value to the previously stored value (block 2072 c). When themeasured value is different from the previously stored value, thecontroller (2060) may update the previously stored value (block 2072 d).When no value is previously recorded, the controller (2060) may storethe measured value into the memory (2060). In certain circumstances, thecontroller (2060) may provide visual feedback to a user of the surgicalinstrument (2050) as to the measured state of charge of the battery(2058). For example, the controller (2060) may display the measuredvalue of the state of charge of the battery (2058) on an LCD displayscreen that, in some circumstances, can be integrated with theinterchangeable working assembly (2054) (block 2072 e).

Further to the above, the module (2072) also can be executed by othercontrollers upon coupling the interchangeable working assemblies of suchother controllers to the power assembly (2056). For example, a user maydisconnect the interchangeable working assembly (2054) from the powerassembly (2056). The user may then connect another interchangeableworking assembly comprising another controller to the power assembly(2056). Such controller may in turn utilize the coulomb counting circuit(2070) to measure the state of charge of the battery (2058) and may thenaccess the memory (2060) and determine whether a previous value for thestate of charge of the battery (2058) is stored in the memory (2060)such as, for example, a value entered by the controller (2060) while theinterchangeable working assembly (2054) was coupled to the powerassembly (2056). When a previous value is detected, the controller maycompare the measured value to the previously stored value. When themeasured value is different from the previously stored value, thecontroller may update the previously stored value.

D. Exemplary Power Modulation Circuit and Method

FIGS. 17-19 show an exemplary circuit diagram of an exemplaryalternative power assembly (2096) that may be used with a workingassembly (2094) to form an instrument like instrument (10). Workingassembly (2094) of this example comprises a handle assembly (e.g., likehandle assembly (14) described above, etc.) and a shaft assembly (e.g.,like shaft assembly (200) described above, etc.) extending between thehandle assembly an end effector (e.g., like end effector (300) describedabove, etc.). The interchangeable working assembly (2094) of thisexample also includes a motor (2014) (e.g., like motor (82) describedabove, etc.) and a motor driver (2015) that can be employed to motivatethe closure drive system and/or the firing drive system of theinterchangeable working assembly (2094), for example. The motor (2014)can be powered by a battery (2098) that may reside in the power assembly(2096). The power assembly (2096) may be provided as a variation ofpower source (90) described above.

As illustrated in FIGS. 17 and 18, the battery (2098) may include anumber of battery cells connected in series that can be used as a powersource to power the motor (2014). In certain instances, the batterycells of the power assembly (2096) may be replaceable and/orrechargeable. The battery cells can be Lithium-Ion batteries that can beremovably attached to the power assembly (2096), for example. In use, avoltage polarity provided by the power assembly (2096) can operate themotor (2014) to drive a longitudinally-movable drive member toeffectuate an end effector, such as the end effector (300) describedherein. For example, the motor (2014) can be configured to drive thelongitudinally-movable drive member to advance a cutting member to cuttissue captured by the end effector (300) and/or a firing mechanism tofire staples from a staple cartridge assembled with the end effector(300), for example. The staples can be fired into tissue captured by theend effector (300), for example.

Still referring to FIGS. 17-19, the interchangeable working assembly(2094) may include a working assembly controller (2102); and the powerassembly (2096) may include a power assembly controller (2100). Theworking assembly controller (2102) can be configured to generate one ormore signals to communicate with the power assembly controller (2100).In certain instances, the working assembly controller (2102) maygenerate the one or more signals to communicate with the power assemblycontroller (2100) by modulating power transmission from the powerassembly (2096) to the interchangeable working assembly (2094) while thepower assembly (2096) is coupled to the interchangeable working assembly(2094).

Furthermore, the power assembly controller (2100) can be configured toperform one or more functions in response to receiving the one or moresignals generated by the working assembly controller (2102). Forexample, the interchangeable working assembly (2094) may impose a powerrequirement and the working assembly controller (2102) may be configuredto generate a signal to instruct the power assembly controller (2100) toselect a power output of the battery (2098) in accordance with the powerrequirement of the interchangeable working assembly (2094). The signalcan be generated, as described above, by modulating power transmissionfrom the power assembly (2096) to the interchangeable working assembly(2094) while the power assembly (2096) is coupled to the interchangeableworking assembly (2094). In response to receiving the signal, the powerassembly controller (2100) may set the power output of the battery(2098) to accommodate the power requirement of the interchangeableworking assembly (2094). Those of ordinary skill in the art willappreciate that various interchangeable working assemblies may beutilized with the power assembly (2096). The various interchangeableworking assemblies may impose various power requirements and maygenerate signals unique to their power requirements during theircoupling engagement with the power assembly (2096) to alert the powerassembly controller (2100) to set the power output of the battery (2098)in accordance with their power requirements.

Still referring to FIGS. 17 and 18, the power assembly (2096) mayinclude a power modulator control (2106) that may comprise, for example,one or more field-effect transistors (FETs), a Darlington array, anadjustable amplifier, and/or any other power modulator. The powerassembly controller (2100) may actuate the power modulator control(2106) to set the power output of the battery (2098) to the powerrequirement of the interchangeable working assembly (2094) in responseto the signal generated by working assembly controller (2102) while theinterchangeable working assembly (2094) is coupled to the power assembly(2096).

The power assembly controller (2100) can be configured to monitor powertransmission from the power assembly (2096) to the interchangeableworking assembly (2094) for the one or more signals generated by theworking assembly controller (2102) of the interchangeable workingassembly (2094) while he interchangeable working assembly (2094) iscoupled to the power assembly (2096). As illustrated in FIG. 17, thepower assembly controller (2100) may utilize a voltage monitoringmechanism for monitoring the voltage across the battery (2098) to detectthe one or more signals generated by the working assembly controller(2102), for example. In certain instances, a voltage conditioner can beutilized to scale the voltage of the battery (2098) to be readable by anAnalog to Digital Converter (ADC) of the power assembly controller(2100). As illustrated in FIG. 17, the voltage conditioner may comprisea voltage divider (2108) that can create a reference voltage or a lowvoltage signal proportional to the voltage of the battery (2098) thatcan be measured and reported to the power assembly controller (2100)through the ADC, for example.

In other circumstances, as illustrated in FIG. 18, the power assembly(2096) may comprise a current monitoring mechanism for monitoringcurrent transmitted to the interchangeable working assembly (2094) todetect the one or more signals generated by the working assemblycontroller (2102), for example. In certain instances, the power assembly(2096) may comprise a current sensor (2110) that can be utilized tomonitor current transmitted to the interchangeable working assembly(2094). The monitored current can be reported to the power assemblycontroller (2100) through an ADC, for example. In other circumstances,the power assembly controller (2100) may be configured to simultaneouslymonitor both of the current transmitted to the interchangeable workingassembly (2094) and the corresponding voltage across the battery (2098)to detect the one or more signals generated by the working assemblycontroller (2102). Those of ordinary skill in the art will appreciatethat various other mechanisms for monitoring current and/or voltage canbe utilized by the power assembly controller (2100) to detect the one ormore signals generated by the working assembly controller (2102). Allsuch mechanisms are contemplated by the present disclosure.

As illustrated in FIG. 19, the working assembly controller (2102) can beconfigured to generate the one or more signals for communication withthe power assembly controller (2100) by effectuating the motor driver(2015) to modulate the power transmitted to the motor (2014) from thebattery (2098). As a result, the voltage across the battery (2098)and/or the current drawn from the battery (2098) to power the motor(2014) may include discrete patterns or waveforms that represent the oneor more signals. As described above, the power assembly controller(2100) can be configured to monitor the voltage across the battery(2098) and/or the current drawn from the battery (2098) for the one ormore signals generated by the working assembly controller (2102).

Upon detecting a signal, the power assembly controller (2100) can beconfigured to pedal in one or more functions that correspond to thedetected signal. In at least one example, upon detecting a first signal,the power assembly controller (2100) can be configured to actuate thepower modulator control (2106) to set the power output of the battery(2098) to a first duty cycle. In at least one example, upon detecting asecond signal, the power assembly controller (2100) can be configured toactuate the power modulator control (2106) to set the power output ofthe battery (2098) to a second duty cycle different from the first dutycycle.

Referring now to FIGS. 17 and 18, the power assembly (2096) may comprisea switch (2104) that can be switchable between an open position and aclosed position. The switch (2104) can be transitioned from the openposition to the closed positioned when the power assembly (2096) iscoupled with the interchangeable working assembly (2094), for example.In certain instances, the switch (2104) can be manually transitionedfrom the open position to the closed position after the power assembly(2096) is coupled with the interchangeable working assembly (2094), forexample. While the switch (2104) is in the open position, components ofthe power assembly (2096) may draw sufficiently low or no power toretain capacity of the battery (2098) for clinical use. The switch(2104) can be a mechanical, reed, hall, or any other suitable switchingmechanism. Furthermore, in certain circumstances, the power assembly(2096) may include an optional power supply (2105) that may beconfigured to provide sufficient power to various components of thepower assembly (2096) during use of the battery (2098). Similarly, theinterchangeable working assembly (2094) also may include an optionalpower supply (2107) that can be configured to provide sufficient powerto various components of the interchangeable working assembly (2094).

In an exemplary method, as illustrated in FIG. 20, the power assembly(2096) can be coupled to the interchangeable working assembly (2094)(block 2101). In certain instances, as described above, the switch(2104) can be transitioned to the closed configuration to electricallyconnect the interchangeable working assembly (2094) to the powerassembly (2096). In response, the interchangeable working assembly(2094) may power up and may, at least initially, draw relatively lowcurrent from the battery (2098) (block 2101 a-1). For example, theinterchangeable working assembly (2094) may draw less than or equal to 1ampere to power various components of the interchangeable workingassembly (2094). In certain instances, the power assembly (2096) alsomay power up as the switch (2014) is transitioned to the closed position(block 2101 b-1) while interchangeable working assembly (2094) powersup. In response, the power assembly controller (2100) may begin tomonitor current drawn by the interchangeable working assembly (2094), asdescribed in greater detail above, by monitoring voltage across thebattery (2098) and/or current transmission from the battery (2098) tothe interchangeable working assembly (2094), for example.

To generate and transmit a communication signal to the power assemblycontroller (2100) via power modulation, the working assembly controller(2102) may employ the motor drive (2015) to pulse power to the motor(2014) (block 2101 a-2) in patterns or waveforms of power spikes, forexample. In certain circumstances, the working assembly controller(2102) can be configured to communicate with the motor driver (2015) torapidly switch the direction of motion of the motor (2014) by rapidlyswitching the voltage polarity across the windings of the motor (2014)to limit the effective current transmission to the motor (2014)resulting from the power spikes. In result, as illustrated in FIG. 21C,the effective motor displacement resulting from the power spikes can bereduced to minimize effective displacement of a drive system of thesurgical instrument (2090) that is coupled to the motor (2014) inresponse to the power spikes.

Further to the above, the working assembly controller (2102) maycommunicate with the power assembly controller (2100) by employing themotor driver (2015) to draw power from the battery (2098) in spikesarranged in predetermined packets or groups that can be repeated overpredetermined time periods to form patterns detectable by the powerassembly controller (2100). For example, as illustrated in FIGS. 21A and21B, the power assembly controller (2100) can be configured to monitorvoltage across the battery (2100) for predetermined voltage patternssuch as, for example, the voltage pattern (2103) (FIG. 21A) and/orpredetermined current patterns such as, for example, the current pattern(2109) (FIG. 21B) using voltage and/or current monitoring mechanisms asdescribed in greater detail above (blocks 2101 b-2). Furthermore, thepower assembly controller (2100) can be configured to execute one ormore algorithms and/or functions upon detecting of a pattern of currentpulses (block 2101 a-3). Those of ordinary skill in the art willappreciate that the communication between the power assembly controller(2100) and the working assembly controller (2102) via power transmissionmodulation may reduce the number of connection lines needed between theinterchangeable working assembly (2094) and the power assembly (2096).

In certain circumstances, the power assembly (2096) can be employed withvarious interchangeable working assemblies of multiple generations thatmay have different power requirements. Some of the variousinterchangeable workings assemblies may comprise communication systems,as described above, while others may lack such communication systems.For example, the power assembly (2096) can be utilized with a primaryinterchangeable working assembly that lacks the communication systemdescribed above. Alternatively, the power assembly (2096) can beutilized with a secondary interchangeable working assembly such as, forexample, the interchangeable working assembly (2094) that comprises acommunication system, as described above. Thus, the power assembly(2096) may be configured to provide power to a working assemblyregardless of whether the working assembly has a communication system asdescribed above.

Further to the above, the primary interchangeable working assembly mayhave a first power requirement and the secondary interchangeable workingassembly may have a second power requirement that can be different fromthe first power requirement. For example, the first power requirementmay be less than the second power requirement. To accommodate the firstpower requirement of the primary interchangeable working assembly andthe second power requirement of the secondary interchangeable workingassembly, the power assembly (2096) may comprise a first power mode foruse with the primary interchangeable working assembly and a second powermode for use with the secondary interchangeable working assembly. Incertain instances, the power assembly (2096) can be configured tooperate at a default first power mode corresponding to the powerrequirement of the primary interchangeable working assembly. As such,when a primary interchangeable working assembly is connected to thepower assembly (2096), the default first power mode of the powerassembly (2096) may accommodate the first power requirement of theprimary interchangeable working assembly. However, when a secondaryinterchangeable working assembly such as, for example, theinterchangeable working assembly (2094), is connected to the powerassembly (2096), the working assembly controller (2102) of theinterchangeable working assembly (2094) may communicate, as describedabove, with the power assembly controller (2100) of the power assembly(2096) to switch the power assembly (2096) to the second power mode toaccommodate the second power requirement of the interchangeable workingassembly (2094). Those of ordinary skill in the art will appreciate thatsince the primary interchangeable working assembly lacks the ability togenerate a communication signal, the power assembly (2096) will remainin the default first power mode while connected to the primaryinterchangeable working assembly.

As described above, the battery (2098) can be rechargeable. In certaincircumstances, it may be desirable to drain the battery (2098) prior toshipping the power assembly (2096). A dedicated drainage circuit can beactivated to drain the battery (2098) in preparation for shipping of thepower assembly (2096). Upon reaching its final destination, the battery(2098) can be recharged for use during a surgical procedure. However,the drainage circuit may continue to consume energy from the battery(2098) during clinical use. In certain circumstances, theinterchangeable working assembly controller (2102) can be configured totransmit a drainage circuit deactivation signal to the power assemblycontroller (2100) by modulating power transmission from the battery(2098) to the motor (2014), as described in greater detail above. Thepower assembly controller (2100) can be programmed to deactivate thedrainage circuit to prevent drainage of the battery (2098) by thedrainage circuit in response to the drainage circuit deactivationsignal, for example. The reader will appreciate that variouscommunication signals can be generated by the working assemblycontroller (2102) to instruct the power assembly controller (2100) topedal various functions while the power assembly (2096) is coupled tothe interchangeable working assembly (2094).

Referring again to FIGS. 17-19, the power assembly controller (2100)and/or the working assembly controller (2102) may comprise one or moreprocessors and/or memory units that may store a number of softwaremodules. Although certain modules and/or blocks of the surgicalinstrument (2050) may be described by way of example, it can beappreciated that a greater or lesser number of modules and/or blocks maybe used. Further, although various instances may be described in tennisof modules and/or blocks to facilitate description, such modules and/orblocks may be implemented by one or more hardware components, e.g.,processors, DSPs, PLDs, ASICs, circuits, registers and/or softwarecomponents, e.g., programs, subroutines, logic and/or combinations ofhardware and software components.

III. Exemplary Battery Pack Circuits and Methods of Operation

FIG. 22 shows a schematic diagram of a circuit (3010) that may beprovided by power pack (92). Circuit (3010) includes a set of powercells (3012), which are provided by batteries (98) in this example; aneffective series resistor (3014), which may be provided by variouselectrical components as will be apparent to those of ordinary skill inthe art in view of the teachings herein; and a pair of terminals (3018a, 3018 b), which may be provided as a set of contacts that are exposedthrough distal housing portion (96). Terminals (3018 a, 3018 b) may becoupled with complementary contacts in handle assembly (14), which isrepresented in FIG. 22 by a symbol for a load resistor (3016). Asdescribed above, power pack (92), and hence circuit (3010), provideselectrical power that is operable to drive motor (82) and otherelectrical components of instrument (10). In the present example, powercells (3012) are non-rechargeable. Power pack (92) is thus provided andconfigured for disposal after the power from cells (3012)/batteries (98)has been consumed. In other words, power pack (92) is provided withinstrument (10) as a “primary” battery pack, such that power pack (92)is intended to be the first (and only) battery pack that is to be usedwith instrument (10). In some versions, power pack (92) and otherdevices referred herein to as “primary” battery packs or “primary” powerpacks/sources comprise one or more non-rechargeable batteries. As willbe understood by a person skilled in the art, as shown in FIG. 22, thevalue “V” represents the open circuit voltage of cells (3012), the value“R_(S)” represents the effective series resistance provided by effectiveseries resistor (3014), the value “R_(L)” represents the load resistanceimposed by motor (82) and other electrical components of instrument(10), the value “V_(L)” represents the load voltage of motor (82) andother electrical components of instrument (10), and the value “I”represents the =current drawn through circuit (3010). As will be furtherunderstood by a person skilled in the art, the load voltage (V_(L)) maybe calculated as V_(L)=IR_(L). The current (I) may be calculated asI=V/(R_(S)+R_(L)). The load voltage (V_(L)) may thus be furthercalculated as V_(L)=VR_(L)/(R_(S)+R_(L)).

An exemplary plot of load resistance (R_(L)) versus load voltage (V_(L))is shown in FIG. 23. As shown, the load voltage (V_(L)) increases in anon-linear fashion as the load resistance (R_(L)) increases, such thatthe load voltage (V_(L)) approaches but does not reach the open circuitvoltage (V).

In some instances, a medical device may be configured to detect batterypack characteristics in order to detect battery health, to confirmproper insertion of the battery pack, to confirm that an appropriatebattery pack is inserted, etc. In instances, it may be desirable for amedical device to be operable to confirm that an appropriate batterypack is inserted in order to confirm that the battery pack is notintended for use in another device, in order to confirm that acounterfeit battery pack is not being used, an/or for other reasons. Inthe context of instrument (10), one or more features on circuit board(100), other features of handle assembly (14), and/or other features ofinstrument (10) may detect one or more characteristics of power pack(92). By way of example only, one or more features on circuit board(100), other features of handle assembly (14), and/or other features ofinstrument (10) may be configured to detect the effective seriesresistance (R_(S)) provided by effective series resistor (3014). Inaddition or in the alternative, one or more features on circuit board(100), other features of handle assembly (14), and/or other features ofinstrument (10) may be configured to detect the open circuit voltage (V)of cells (3102). In either or both cases, the detection may be performedto ensure than an appropriate power pack (92) has been coupled withhandle assembly (14).

Medical devices such as instrument (10) may be indicated for multipleuses and, as a result, may require sterilization between uses. Some suchdevices may be designed to utilize a non-rechargeable battery thateither cannot be sterilized or simply would not be sterilized for avariety of reasons. In some instances, it may be advantageous foreconomic, environmental, and/or various other reasons to utilize arechargeable battery in a medical device instead of using anon-rechargeable battery in the medical device. It may further bedesirable to utilize a rechargeable battery that is universal in naturesuch that the battery is configured to be used in various kinds ofmedical devices (e.g., instrument (10) and other kinds of medicaldevices). However, in some medical devices this may not be possible dueto battery detection features that may be present in the medical device.In other words, as noted above, some medical devices may be equippedwith features (e.g., mechanisms and/or software, etc.) that detectcharacteristics of a connected battery and/or interrogate a connectedbattery. If certain characteristics are not detected and/or the batterypack does not properly respond to the interrogations, the medical devicemay prevent the battery from being properly electrically connected tothe medical device. Alternatively, the medical device may not operateproperly if the medical device does not detect the appropriatecharacteristics and/or interrogation response.

In view of the foregoing, it may be desirable to provide a secondarybattery pack that may be used to replace a primary battery pack that isprovided with a medical device such as instrument (10). In the examplesdescribed herein, it is contemplated that the “secondary” battery packs(or “secondary” power packs/sources) described herein comprise one ormore rechargeable batteries; while the “primary” battery packs (or“primary” power packs/sources) described herein comprise one or morenon-rechargeable batteries. Of course, “secondary” battery packs (or“secondary” power packs/sources) described herein may instead compriseone or more non-rechargeable batteries; and/or “primary” battery packs(or “primary” power packs/sources) described herein may instead compriseone or more rechargeable batteries. Either way, it is contemplated thata secondary battery pack may be configured to express thecharacteristics and/or interrogation response that the medical device(e.g., instrument (10), etc.) would expect from a legitimate primarybattery pack (e.g., power pack (92), etc.). Such a secondary batterypack may also be configured for use in various kinds of medical devicesthat have different expectations for their respective primary batterypacks. The secondary battery pack may thus determine what theexpectations of a medical device are and then adapt to thoseexpectations on an ad hoc basis. Various examples of how a secondarybattery pack may be configured and operable are described in greaterdetail below. Other examples will be apparent to those of ordinary skillin the art in view of the teachings herein.

A. Exemplary Secondary Battery Pack with Primary Battery Pack EmulationFeatures

FIG. 24 shows a schematic circuit diagram of an exemplary alternativepower assembly (3100). Power assembly (3100) is configured to respond toan interrogation by a medical device to which it is connected in amanner that emulates a primary power assembly (i.e., a primary powerpack (92)), thereby convincing the medical device that the secondarypower assembly (3100) is a primary power pack (92). The physicalappearance and other features of the power assembly (3100) may beconfigured according to the teachings above. For instance, the powerassembly (3100) may be configured in a similar manner to thebattery/power pack (92) shown in FIG. 4, but is not so limited. Powerassembly (3100) may thus be mechanically and electrically coupled withthe proximal end of handle assembly (14) in a manner similar to powerpack (92). In the present example, the power assembly (3100) includes aset of battery cells (3102) that are operable to provide power outputthrough positive and negative output terminals (3104 a, 3104 b). Batterycells (3102) may be rechargeable or non-rechargeable. Terminals (3104 a,3104 b) may be provided as a set of contacts that are exposed through adistal housing portion of power assembly (3100) (e.g., similar to distalhousing portion (96)). Terminals (3104 a, 3104 b) may thus be coupledwith complementary contacts in a handle assembly (14), handle assembly(2002), working assembly (2054), etc., which are represented in FIG. 24by a symbol for a load resistor (3114). It should be understood thatterminals (3104 a, 3104 b) may also be coupled with complementarycontacts in various other kinds of medical devices, not just surgicalstapling instruments (10).

In the example shown, power assembly (3100) also includes a voltageregulator (3106), a NPN pass transistor (3108), a first sensor (3110),and a second sensor (3112). The power assembly (3100) further includes aprocessor (3116) in communication with each of the voltage regulator(3106), the pass transistor (3108), the first sensor (3110), and thesecond sensor (3112). In the example shown, the first sensor (3110) is acurrent sensor that is configured to sense the current level drawnthrough the circuit and communicate the sensed current to the processor(3116). The second sensor (3112) is a voltage sensor that is configuredto sense the voltage of the circuit and communicate the sensed voltageto the processor (3116). Various suitable kinds of components that maybe used to form sensors (3110, 3112) will be apparent to those ofordinary skill in the art in view of the teachings herein. It will alsobe appreciated that various other components and features may be usedfor monitoring and altering current and/or voltage in the power assembly(3100). Various suitable kinds of components that may be used to formvoltage regulator (3106), pass transistor (3108), and processor (3116)will also be apparent to those of ordinary skill in the art in view ofthe teachings herein. By way of example only, voltage regulator (3106)may comprise a buck regulator, a boost regulator, and/or any othersuitable kind of regulator(s). It should be understood that thecomponents of power assembly (3100) may be operable to provide analogsignal processing, digital signal processing, data storage, controllablyvariable output impedance, controllably variable output voltage,controllably variable current, and/or other functionality. Varioussuitable ways in which power assembly (3100) may provide suchfunctionality will be apparent to those of ordinary skill in the art inview of the teachings herein.

While some versions of power assembly (3100) may be compatible withvarious kinds of medical devices in addition to being compatible withinstrument (10), the following examples will be provided in the contextof instrument (10) by way of illustration.

Upon coupling the power assembly (3100) to the handle assembly (14), thehandle assembly (14) may detect that the power assembly (3100) iscoupled with the handle assembly (14). In addition or in thealternative, the power assembly (3100) may detect that the powerassembly is coupled with the handle assembly (14) as soon as thosecomponents are coupled together. For instance, in some examples, thepower assembly (3100) and/or the handle assembly (14) could include oneor more contact sensors that are actuated upon insertion of powerassembly (3100) in handle assembly (14). In addition or in thealternative, power assembly (3100) may automatically periodically checkfor electrical continuity across terminals (3104 a, 3104 b), such thatthe presence of electrical continuity across terminals (3104 a, 3104 b)will indicate that power assembly (3100) is coupled with handle assembly(14). In addition or in the alternative, power assembly (3100) mayinclude an inductance sensor that is sensitive to metallic componentsbeing brought into close proximity to power assembly (3100), such thatclose proximity of a metallic component will indicate that powerassembly (3100) is coupled with handle assembly (14). Other suitableways in which power assembly (3100) and/or handle assembly (14) maydetect the coupling of power assembly (3100) with handle assembly (14)will be apparent to those of ordinary skill in the art in view of theteachings herein.

In versions where power assembly (3100) is configured to detect thatpower assembly (3100) has been coupled with instrument (10), powerassembly (3100) may also be configured to carry out a process todetermine what kind of instrument (10) power assembly (3100) is coupledwith, such as by sensing characteristics of the instrument (10) asdescribed in greater detail below with reference to FIGS. 26 through28-2. In addition or in the alternative, in versions where instrument(10) is configured to detect that power assembly (3100) has been coupledwith instrument (10), circuit board (100) and/or other electricalcomponents of instrument (10) may generate one or more signals tocommunicate with the power assembly (3100) in order to interrogate thepower assembly (3100). This interrogation may be performed as part of aninitialization routine, boot up routine, self-test, or similar routinebefore instrument (10) is fully operable by a human or robotic operator.In certain instances, the instrument (10) may generate the one or moresignals to interrogate or communicate with the power assembly (3100) bymodulating power transmission from the power assembly (3100) to theinstrument (10) while the power assembly (3100) is coupled to theinstrument (10). By way of example only, instrument (10) may send theone or more interrogation signals in order to determine whether powerassembly (3100) is a primary power pack (92). In addition or in thealternative, instrument (10) may interrogate power assembly (3100) todetermine if the power assembly (3100) is compatible with the instrument(10). In addition or in the alternative, instrument (10) may interrogatepower assembly (3100) to determine battery health, whether powerassembly (3100) is properly inserted, and/or other conditions. Based onthe results of the interrogation, instrument (10) may be configured toprevent the use of a counterfeit power pack/assembly or a powerpack/assembly that is otherwise perceived as improper by instrument(10).

The power assembly (3100) of the present example is configured toperform one or more functions in response to receiving the one or moreinterrogation signals from the instrument (10) in order to convinceinstrument (10) that power assembly (3100) is a primary power pack (92)and/or to otherwise convince instrument (10) that power assembly (3100)is compatible with instrument (10). Therefore, it may be desirable toprovide a power assembly (3100) that is configured to emulate the powerprofile of a primary power pack (92).

FIG. 25 shows an exemplary method of emulating a power profile of aprimary power pack (92) that is intended for use with instrument (10).It should be understood that the method shown in FIG. 25 may be carriedout using the circuit of power assembly (3100) shown in FIG. 24 or usingvarious other circuit arrangements. Various suitable ways in which themethod shown in FIG. 25 may be carried out using the circuit of powerassembly (3100) shown in FIG. 24 and/or using various other circuitarrangements will be apparent to those of ordinary skill in the art inview of the teachings herein. When a user connects a battery pack, suchas the power assembly (3100), to the instrument (10) (e.g., handleassembly (14), etc.) (block 3150), the instrument (10) may sense that apower assembly (3100) is connected thereto, as noted above. In theexample shown, the interrogation is received by the power assembly(3100) (block 3152). If the interrogation is understood by the processor(3116) of power assembly (3100) (block 3154) and if the processor (3116)is programmed to respond to the interrogation (block 3156), theprocessor (3116) sends the expected response or interrogation output tothe instrument (10) (block 3158). The expected response from powerassembly (3100) is meant to emulate the effective series resistance(R_(S)) of a primary power pack (92) as described above. Thus, byconditioning the load voltage output (V_(L)), assuming that loadresistance (R_(L)) and open circuit voltage (V) would be the same asthey would be with a primary power pack (92), the power assembly (3100)can convince instrument (10) that the effective series resistance(R_(S)) of the power assembly (3100) has the same value of an effectiveseries resistance (R_(S)) as expected from a primary power pack (92). Byaltering the load voltage output (V_(L)), the circuit board (100), otherfeatures of handle assembly (14), and/or other features of instrument(10) receives a voltage signal according to an assumed effective seriesresistance (R_(S)) value.

Placing the method shown in FIG. 25 further in context with the circuitshown in FIG. 24, in some versions the processor (3116) may receive asignal that the power assembly (3100) is connected to a handle assembly(14) and detect an interrogation by the handle assembly (14). Theprocessor (3116) may then command the voltage regulator (3104) to adjustthe load voltage (V_(L)) at the expected level associated with theexpected effective series resistance (R_(S)) value, for example. The NPNpass transistor (3108) may also be configured to provide an outputimpedance that emulates the expected effective series resistance(R_(S)).

Continuing further with the method shown in FIG. 25, if the load voltageoutput (V_(L)) and thus the effective series resistance (R_(S)) value iswithin a range of what is expected by the instrument (10) and theinstrument (10) believes that a primary power pack (92) is connected(block 3160), then the power assembly (3100) initiates a voltage andcurrent profile associated with the instrument (10) (block 3162). Thevoltage and current profile associated with the shaft assembly may beconstant or variable, and may be stored on a database, such as adatabase or other storage medium on a memory (not shown). The memoryand/or database may be present on or in the power assembly (3100)itself. Alternatively or additionally, the database or part of thedatabase may be in a nearby or remote memory and accessed according tomethods that will be apparent to those skilled in the art. Additionallyor alternatively, the power assembly (3100) may be configured tocommunicate electronically (wired, wirelessly, or otherwise) with othersources of information (e.g., manufacturer's specifications) in order todiscover and/or initiate an operational profile associated with thedevice.

If however, the instrument (10) does not believe that power assembly(3100) is a primary power pack (92), then an error warning mayoptionally be provided (block 3164). The error warning may be providedby a visual, audio, and/or another indicative manner to the user; andmay be provided through the power assembly (3100) and/or through theinstrument (10) that is connected to the power assembly (3100). If thepower assembly (3100) has performed less than a certain number ofinterrogation cycles (e.g., two), the power assembly (3100) may suspendoperation (block 3166). Alternatively, if the instrument (10) does notbelieve a primary power pack (92) is connected, then anotherinterrogation cycle may begin (block 3152), with or without an errorwarning (block 3164).

Referring back to the stage where it is determined whether theinterrogation from instrument (10) is understood by processor (3116) ofpower assembly (3100)(block 3154), if the interrogation is notunderstood by the processor (3116), then the power assembly (3100)collects and stores information regarding the interrogation (block 3168)and may use the collected and stored information to re-program theprocessor (block 3170) in order to increase the chances that, during thenext interrogation cycle, the processor (3166) understands theinterrogation and/or is programmed to appropriately respond to theinterrogation. In some examples, powering the instrument (10) on and offmay allow software and/or algorithms within the power assembly (3100)(e.g., in the processor (3116)) to adapt and update in order to attemptto match the expectations of the instrument (10), but powering theinstrument (10) on and off is not required for the power assembly (3100)to update as described.

In some examples, the step(s) of collection and storage of suchinformation may be performed using a memory (not shown) on the powerassembly (3100) itself, which then may communicate to parties such asthe power assembly (3100) designer and manufacturer. For instance, theinformation could be transmitted back to a centralized system once thepower assembly (3100) is coupled with, for example, a recharging/dockingstation. By way of example only, the recharging/docking station may bein communication with a centralized server or other processing systemcomponent via the internet, via a private network, via a cellularnetwork, and/or via any other suitable means. Information collected frompower assembly (3100) may be used to refine the performance of thatparticular power assembly (3100). In addition or in the alternative, theinformation may be used to improve the performance of other existingpower assemblies (3100) and/or subsequently made power assemblies(3100). The information may be stored and used in any software oralgorithms used in a power assembly (3100) such as one of the examplesdescribed herein; or in some other fashion. In instances where theinformation is received by a central station, the information may beconveyed from a central processor or database to other power assemblies(3100) in any suitable manner as will be apparent to those skilled inthe art. While FIG. 25 shows that the collection and storage ofinformation (block 3168) occurs when interrogation is not understood bythe processor (3166) (block 3154) or if the processor (3166) is notprogrammed to respond to the interrogation (block 3156), suchinformation may also be collected and stored at other stages of theinterrogation cycle, for example.

In addition to or as an alternative to the data processing describedabove, power assembly (3100) may monitor duty cycle and usage data andmay be operable to transmit such data to a centralized system when thepower assembly (3100) is coupled with, for example, a recharging/dockingstation. The data may be used to modify certain characteristics of theparticular power assembly (3100), to improve the performance of otherexisting power assemblies (3100), and/or to improve the performance ofsubsequently made power assemblies (3100). For example, the data may beused to modify the steady-state outputs of current or future powerassemblies (3100) in order to maximize battery life, cell balance, andcapacity based on cumulative data usage over time. Additionally oralternatively, when the power assembly (3100) is coupled with arecharging/docking station, bios or simple software updates may beuploaded to the power assembly (3100) as the power assembly manufacturerupdates the operation algorithms and/or programs, or adds new medicaldevices whose primary power assemblies the secondary power assembly(3100) can emulate. In instances where a recharging/docking station isin communication with a manufacturer system and/or other kind of remotesystem, the communication link may be wired or wireless.

B. Exemplary Alternative Battery Pack with Instrument Detection Features

FIG. 26 shows a schematic circuit diagram of another exemplaryalternative power assembly (5010) that includes features that allows thepower assembly (5010) to be used to provide power to a variety of kindsof medical devices having different power requirements. By way ofexample only, power assembly (5010) may be operable to provide power tosurgical stapling instruments such as instrument (10), ultrasonicsurgical instruments such as any of the various ultrasonic surgicalinstruments provided by Ethicon Endo-Surgery, Inc. of Cincinnati, Ohio,electrosurgical instruments such as any of the various electrosurgicalinstruments provided by Ethicon Endo-Surgery, Inc. of Cincinnati, Ohio,and/or any other kind of electrically powered medical devices. Thephysical appearance and other features of the power assembly (5010) maybe configured according to the teachings above. For instance, the powerassembly (5010) may be configured in a similar manner to thebattery/power pack (92) shown in FIG. 4, but is not so limited. Powerassembly (5010) may thus be mechanically and electrically coupled withthe proximal end of handle assembly (14) in a manner similar to powerpack (92).

The power assembly (5010) of the present example includes one or morefeatures that enable it to sense or observe certain characteristics amedical device to which it is connected and adjust its own configurationin an attempt to become operationally compatible with the device. Insome versions, the power assembly (5010) also includes features thatenable it to adapt and learn after successful and unsuccessful attemptsto become operationally compatible with the medical device to increasethe likelihood of success of subsequent attempts with the same ordifferent medical devices. It should be understood that power assembly(5010) may have the same components and functionalities described abovewith respect to power assembly (3100). Power assembly (5010) may thus becapable of convincing a medical device (e.g., instrument (10)) thatpower assembly (5010) is a primary power pack (92) that was originallyprovided with the medical device or that the medical device otherwiseexpects to be coupled with the medical device.

As shown, power assembly (5010) includes a set of battery cells (5012)that are operable to provide power output through terminals (5014 a,5014 b). Battery cells (5012) may be rechargeable or non-rechargeable.Terminals (5014 a, 5014 b) may be provided as a set of contacts that areexposed through a distal housing portion of power assembly (5010) (e.g.,similar to distal housing portion (96)). Terminals (5014 a, 5014 b) maythus be coupled with complementary contacts of a medical device (e.g.,contacts in handle assembly (14), handle assembly (2002), workingassembly (2054), etc.). As will be described in greater detail below,terminals (5014 a, 5014 b) do not have predetermined polarity in thisexample, such that the polarity may be assigned on an ad hoc basis. Inparticular, the circuit includes a set of switches (5030, 5032, 5034,5036) that are interposed between terminals (5014 a, 5014 b) and therest of the circuit of power assembly (5010). The circuit of powerassembly (5010) is configured to provide switches (5030, 5034) in aclosed state, while switches (5032, 5036) are in an open state, in orderto provide terminals (5014 a, 5014 b) at a first polarity (A). Thecircuit of power assembly (5010) is further configured to provideswitches (5032, 5036) in a closed state, while switches (5030, 5034) arein an open state, in order to provide terminals (5014 a, 5014 b) at asecond polarity (B). Power assembly (5010) is operable to switch betweenthese polarities (A, B) on an ad hoc basis in order to render powerassembly (5010) operable with a variety of working assemblies (2054)and/or handle assemblies (14, 2002) having different power requirements.Examples of components and methods through which power assembly (5010)provides this polarity switching will be described in greater detailbelow.

In some examples, power assembly (5010) has the ability to observe orsense certain physical, electrical, electronic, or other characteristicsof the medical device to which power assembly (5010) is coupled andadjust (or maintain) the polarity of the output terminals (5014 a, 5014b) accordingly. In the example shown, the power assembly (5010) isconfigured to sense electrical characteristics of the medical device towhich power assembly (5010) is coupled. Power assembly (5010) includes avoltage regulator (5016), a current regulator (5018), a sensor (5020)positioned to receive a return signal from the output terminals (5014 a,5014 b) when the power assembly (5010) is connected to assembly medical,discussed in further detail below. A processor (5022) included in thepower assembly (5010) communicates with the sensor (5020) and determineswhether the return signal is appropriate based on the output signalsent, such as whether the polarity of the power assembly (5010) matchesthe polarity of the medical device. Power assembly (5010) also includesa warning device (5024) that is configured to provide a warning in avisual, audio, and/or another indicative manner. Various suitable kindsof components that may be used to form voltage regulator (5016), currentregulator (5018), sensor (5020), processor (5022), and warning device(5024) will also be apparent to those of ordinary skill in the art inview of the teachings herein.

FIG. 27 shows an exemplary method that may be carried out by powerassembly (5010). As shown, the method begins with a user connectingpower assembly (5010) with a medical device (block 5050). Power assembly(5010) may detect this coupling in accordance with the teachings abovewith respect to power assembly (3100). Alternatively, power assembly(5010) may detect the coupling of power assembly (5010) with the medicaldevice in any other suitable fashion as will be apparent to those ofordinary skill in the art in view of the teachings herein. In theexample shown in FIGS. 26 and 27, after power assembly (5010) detectsthe coupling of power assembly (5010) with the medical device, powerassembly (5010) begins an interrogation cycle of the medical device bysending an output signal to the medical device, via the output terminals(5014 a, 5014 b) of power assembly (5010) (block 5052). In someexamples, the output signal is set to a first level of voltage by thevoltage regulator (5016) as controlled by the processor (5022), withswitches (5030, 5032, 5034, 5036) providing output terminals (4014 s,5014 b) at a default polarity (A, B). In some such examples, the firstlevel of voltage is insufficient to power the medical device for normaluse; and may be low enough such that the medical device does not evendetect the first level of voltage. This relatively low, first level ofvoltage may be deemed a “polling” voltage.

The voltage level of the signal is increased (block 5052) by the voltageregulator (5016) according to an input from the processor (5022). Thesensor (5020) senses a return signal from the output terminals (5014 a,5014 b) and communicates the return signal to the processor (5022). Inone example, the sensor (5020) is a current sensor and therefore sensesthe current drawn by the medical device. However, in other examples,sensor (5020) may be a different type of sensor that senses differentelectrical or electronic characteristics of the return signal. In thepresent example, the processor (5022), based on the return signal,determines whether the medical device is drawing an appropriate amountof current according to, for example, a start-up operation of themedical device (block 5054). Determining whether the medical device isdrawing an appropriate amount of current based at least in part on theoutput signal allows the power assembly (5010) to determine whether thepolarities of the terminals (5014 a, 5014 b) and the medical device arematching at that stage.

If the medical device is drawing current at a different level thanexpected, for example, the power assembly (5010) may decrease thevoltage output and monitor response of the medical device (block 5056).On the other hand, if the medical device begins to draw current at anexpected level, then the medical device is known to the power assembly(5010) and the power assembly (5010) initiates an operational profile(e.g., current and voltage) associated with the known device. In theexample shown, if the power assembly (5010) has performed less than acertain number of interrogation cycles (e.g., one or more), the powerassembly (5010) switches polarities from the first polarity (A) to thesecond polarity (B), for example (block 5058). Once the polarity of theterminals (5014 a, 5014 b) has been switched, the power assembly (5010)may then begin another interrogation cycle, starting at block 5052, byincreasing the voltage output from the power assembly (5010) to theshaft assembly as described herein. If, however, the power assembly(5010) has already performed a certain number of interrogation cycles,the power assembly (5010) may decide not to switch polarity of thecontacts, and instead may provide an error warning to the user (block5060) and/or suspend operation (block 5062). The error warning may beprovided by a visual, audio, and/or another indicative manner to theuser and may be provided on one or both of the power assembly (5010)(e.g., via warning device (5024)) or the medical device; or on a deviceconnected to one of the power assembly (5010) or the medical device. Thenumber of interrogation cycles before providing an error warning may betwo such that the power assembly (5010) has attempted to properlyelectrically connect with the medical device by switching between thefirst and second polarities (A, B). In some other versions, the numberof interrogation cycles may be a different amount than two, and may bemany more, as described below.

Referring back to the stage shown in block 5054, if the medical deviceis drawing an appropriate amount of current, operation continues and theprocessor (5022) may command the voltage regulator (5016) to increasethe voltage output until the medical device powers on (block 5064). Atthis point, the processor (5022) may initiate the voltage and currentprofile associated with the medical device (block 5066) to initiateoperation of the medical device. The power assembly (5010) optionallymay observe or sense other characteristics of the medical device (block5068) and confirm the identity of the medical device based on thosecharacteristics (block 5070), in a manner discussed in more detailbelow, prior to initiating the voltage and current profile (block 5066).For instance, power assembly (5100) may initially provide a gradualvoltage increase to detect if the medical device includes a reversepolarity protection circuit (e.g., a diode) that has been activated.

Once the identity of the medical device is confirmed, power assembly(5010) may subsequently initiate the voltage and current profileassociated with the medical device (block 5066). In that regard, in theexample shown in FIG. 26, the processor (5022) may set the voltageregulator (5016) and/or the current regulator (5018) to operation levelsassociated with the medical device. The voltage and current profileassociated with the medical device may be constant or variable, and maybe stored on a database, such as a database or other storage medium on amemory (not shown). The memory and/or database may be present on or inthe power assembly (5010) itself. Alternatively or additionally, thedatabase or part of the database may be in a nearby or remote memory andaccessed according to methods that will be apparent to those skilled inthe art. Additionally or alternatively, the power assembly (5010) may beconfigured to communicate electronically (wired, wirelessly, orotherwise) with other sources of information (e.g., manufacturer'sspecifications) in order to discover and/or initiate an operationalprofile associated with the medical device.

If the identity of the medical device is not confirmed (block 5070), forexample, such that the power assembly (5010) is unable to confirm theidentity for any variety of reasons, the power assembly (5010) couldprovide an error warning (block 5072) and suspend operation (block5074). By way of example only, the error warning may be provided throughwarning device (5024). Alternatively, the power assembly (5010) couldreturn to (block 5056) and decrease voltage output, and switch thepolarity of terminals (5014 a, 5014 b) according to (block 5058), andbegin another interrogation cycle as described herein (e.g., at block5052).

In some examples, the power assembly (5010) is configured to adapt inthe event that it cannot properly electrically connect to the medicaldevice; e.g., where the initial polarity of polarity of terminals (5014a, 5014 b) does not complement the polarity of the medical device. Inthat regard, still referring to FIG. 27, the power assembly (5010) maycollect and store certain information (block 5076) if the medical deviceis determined to be drawing current at a different level than expected(e.g., at block 5054), for example, or after the device identity is notconfirmed (e.g., at block 5070), or at other stages of the interrogationcycle. In that regard, as shown in block 5076, the power assembly (5010)may optionally collect and store the response of the medical device tothe output signal of the power assembly (5010). Similarly, the powerassembly (5010) may (additionally or alternatively) optionally collectand store the sensed or observed characteristics of the medical device,such as those characteristics described herein or other characteristics.While the flowchart shows that the collection and storage of informationoccurs if the medical device identity is not confirmed (e.g., blocks5070, 5076), such information may also be collected and stored when themedical device identity is confirmed at block 5070, or if the medicaldevice is drawing current at an expected level (block 5054). In otherwords, the power assembly (5010) may collect and store informationwhether or not it is able to successfully electrically connect to themedical device at any point during an interrogation cycle.

The power assembly (5010) may use the stored information in a subsequentattempt to match the polarity (and/or other characteristics) of themedical device to which it is connected. It may store the medical deviceor other device information for later use for itself or other powerassemblies (5010), or both. If using the information in a subsequentattempt to match the polarity of the medical device, the power assembly(5010) may power down the medical device (block 5078) and subsequentlypower up the medical device (block 5080) and begin another interrogationcycle at, for example, (block 5052). In some examples, powering thedevice on and off may allow software and/or algorithms within the powerassembly (5010) (e.g., in the processor (5022), etc.)) to adapt andupdate in order to attempt to match the medical device.

In some examples, the step(s) of collection and storage of suchinformation may be performed using a memory (not shown) on the powerassembly (5010) itself, which then may communicate to parties such asthe power assembly (5010) designer and manufacturer. For instance, theinformation could be transmitted back to a centralized system once thepower assembly (5010) is coupled with, for example, a recharging/dockingstation. By way of example only, the recharging/docking station may bein communication with a centralized server or other processing systemcomponent via the internet, via a private network, via a cellularnetwork, and/or via any other suitable means. Information collected frompower assembly (5010) may be used to refine the performance of thatparticular power assembly (5010). In addition or in the alternative, theinformation may be used to improve the performance of other existingpower assemblies (5010) and/or subsequently made power assemblies(5010). The information may be stored and used in any software oralgorithms used in a power assembly (5010) such as one of the examplesdescribed herein; or in some other fashion. In instances where theinformation is received by a central station, the information may beconveyed from a central processor or database to other power assemblies(5010) in any suitable manner as will be apparent to those skilled inthe art.

In other examples, referring to FIGS. 28-1, in addition or in thealternative to sensing characteristics of a signal from a controller ofa medical device, an interrogation cycle of the power assembly (5010)may include sensing certain other characteristics of the medical device.For example, once the power assembly (5010) is connected to the medicaldevice (block 5100), the power assembly (5010) may be configured tosense other electrical, mechanical, and/or electronic characteristics orproperties of the medical device (block 4012). For example, the powerassembly (5010) may be configured to sense other electricalcharacteristics of the medical device such as internal resistance. Inaddition or in the alternative, the power assembly (5010) may includeone or more inductance sensors configured to sense the presence ofadjacent metallic members on the medical device when the power assembly(5010) is connected to or adjacent to the medical device. Therefore, theinductance sensor(s) may sense the presence (or lack thereof) and/orlocation of metallic contacts, for example, of the medical device anddetermine that it is connected to a particular known device. Othersensors could be employed to sense the physical characteristics (e.g.shape, size, etc.) of the receptacle area of the medical device thatreceives the power assembly (5010). For instance, the power assembly(5010) could include switches or sensors to detect mechanical or otherfeatures of the receptacle area or other portions of the medical device.Additionally or alternatively, the power assembly (5010) could includebar code readers, radiofrequency identification, or other electrical orelectronic devices or sensors that could be used to identify at leastsome characteristics of the medical device or other portions of themedical device.

In some such examples, still referring to FIG. 28-1, the power assembly(5010) may access a database of characteristics of known medical devices(e.g., working assemblies of known medical devices) and compare thesensed characteristic to the characteristics of known medical devices todetermine to which possible medical devices it is connected (block5104). The database may be stored or included on a memory of the powerassembly (5010) itself. Alternatively or additionally, the database orpart of the database may be in a nearby or remote location and accessedaccording to methods that will be apparent to those skilled in the art.The database may include physical, electric, electronic, and othercharacteristics of known medical devices, or may be a collection ofdifferent physical, electric, electronic, or other characteristics thatmay or may not be associated with a particular known medical device. Forexample, the database may have voltage, amp rate, polarity, physicallocation of contacts, and other various information on a number ofmedical devices to which the power assembly (5010) may be connected.

Once the device identity is confirmed (block 5106), the polarity of theterminals (5014 a, 5014 b) may be maintained or adjusted by switches(5030, 5032, 5034, 5036) according to the presumed polarity of themedical device to which the power assembly (5010) believes it isconnected (block 5108). In some examples, the electrical contactsthereof are moved physically with the goal of properly aligning thebattery contacts with the contacts of the medical device. Alternatively,the polarity of the terminals (5014 a, 5014 b) may be switched byswitches (5030, 5032, 5034, 5036). If the medical device identity is notconfirmed at block 5106, for example, such that the power assembly(5010) is unable to confirm the identity for any variety of reasons, thepower assembly (5010) could provide an error warning (block 5110) (e.g.,via warning device (5024)) and suspend operation (block 5112).Alternatively, the power assembly (5010) could return to (block 5056)and decrease voltage output, and switch the polarity of terminals (5014a, 5014 b) according to block 5108, and begin another interrogationcycle as described herein (e.g., at block 5052).

Once the polarity of the terminals (5014 a, 5014 b) has been switched,the power assembly (5100) may then begin another interrogation cycle,starting at block (5052) of FIG. 28-2, by commencing and increasing thevoltage output from the power assembly (5010) to the medical device asdescribed herein with respect to FIG. 27. The interrogation cycle shownin FIG. 28-2 is substantially identical to the interrogation cycle shownin FIG. 27, except that the interrogation cycle of FIG. 28-2 may bepreceded by the initial interrogation cycle described and shown in FIG.28-1, starting at (block 5102), for example. Therefore, blocksrepresenting the same or similar steps are labeled with the samereference numerals. Notably, at block 5058′, the polarity of the device,rather than the battery, is switched (see block 5058, FIG. 27).Moreover, in one example, if the power assembly (5010) is unable toconfirm the medical device identity at (block 5106), the power assembly(5010) may skip the step of adjusting the polarity at (block 5108) andcommence the interrogation cycle starting at block 5052.

Still referring to FIGS. 28-1 and 28-2, when sensing any of theabove-mentioned or other characteristics, the power assembly (5010) maycollect and store any information regarding the response and/orcharacteristics of the medical device and communicate with the databaseto add the observed characteristics of the medical device to thedatabase at various times during the interrogation cycle (e.g., blocks5114, 5116, 5118, 5120). The storage and collection of such informationmay be in a same or similar manner as the collection of informationand/or data shown and describe relative to the method shown in FIG. 27.For example, if the power assembly (5010) is unsuccessful at properlyelectrically connecting with the medical device for any reason, or ifthe power assembly (5010) is successful at properly electricallyconnecting with the medical device, the power assembly (5010) maycollect and store different characteristics that were sensed during aninitial attempt to connect.

IV. Exemplary Alternative Power Processing Features of Medical Device

FIG. 29 shows a schematic circuit diagram of an exemplary alternativemedical device (6010) including features that that allow it to be usedwith a variety of battery packs or other power devices. In someexamples, the device (6010) may be similar to the surgical instrument(10) shown in FIG. 1, but is not so limited. As shown in FIG. 29, thedevice (6010) is schematically shown to be connected to a battery packor power assembly (6012) that may have characteristics (e.g., such aspolarity) that are initially unknown to the device (6010). The device(6010) includes one or more features that enable it to sense or observecertain characteristics of the power assembly (6012) and adjust its ownconfiguration in an attempt to become compatible with the power assembly(6012). As shown, such features are provided in a working assembly(6014) of a medical device (6010), such as working assembly (2054) (FIG.15) described herein. However, these features may be provided in, forexample, different portions of a medical device (6010), such as a handleassembly (e.g., handle assembly 2002 (FIGS. 12-1, 12-2, and 13)), or anyportion of a body of a medical device described herein. Furthermore, thedevice (6010), in some examples, includes features that enable it toadapt and learn after successful and unsuccessful attempts to becomeoperationally compatible with the power assembly (6012) to increase thelikelihood of success of subsequent attempts with the same, similar, ordifferent power assemblies (6012).

In that regard, the working assembly (6014) includes an interface (6015)having a power input (6016) that is configured to be connected to, andreceive power from, an interface (6017) of power assembly (6012) shownin FIG. 29, via terminals (6018 a, 6018 b). Terminals (6018 a, 6018 b)may be provided as a set of contacts that are exposed through a distalhousing portion of working assembly (6014). Terminals (6018 a, 6018 b)may thus be coupled with complementary contacts of a power assembly(6012) (e.g., contacts of power assembly (90)). As will be described ingreater detail below, terminals (6018 a, 6018 b) do not havepredetermined polarity in this example, such that the polarity may beassigned on an ad hoc basis. In particular, the circuit includes a setof switches (6020, 6022, 6024, 6026) that are interposed betweenterminals (6018 a, 6018 b) and the rest of the circuit of workingassembly (6014). The circuit of working assembly (6014) is configured toprovide switches (6020, 6024) in a closed state, while switches (6022,6026) are in an open state, in order to provide terminals (6018 a, 6018b) at a first polarity (A). The circuit of working assembly (6014) isfurther configured to provide switches (6022, 6026) in a closed state,while switches (6020, 6024) are in an open state, in order to provideterminals (6018 a, 6018 b) at a second polarity (B). Working assembly(6014) is operable to switch between these polarities (A, B) on an adhoc basis in order to render working assembly (6014) operable with avariety of power assemblies (e.g., 90, 6012) having differentpolarities. Alternatively, working assembly (6014) may utilize a diodebridge (not shown) that enables the working assembly (6014) to becompatible with power assemblies (e.g., 90, 6012) having any polarityorientation. Examples of components and methods through which workingassembly (6014) provides polarity switching via switches (6020, 6022,6024, 6026) will be described in greater detail below.

In the example shown, the working assembly (6014) of medical device(6010) is configured to sense electrical characteristics of the powerassembly (6012) that is connected to the device (6010). In that regard,the device (6010) includes a sensor (6018) that is operable to sense atleast one characteristic of power assembly (6012). In the embodimentshown, the sensor (6018) is a polarity sensing device (6018) that isoperable to sense the polarity of the power assembly (6012) that isconnected to the working assembly (6014).

FIG. 30 shows an exemplary method that may be carried out by medicaldevice (6010). As shown, the method begins with a user connecting powerassembly (6012) to the medical device (6010) (block 6150). Medicaldevice (6010) may detect this coupling in accordance with the teachingsabove with respect to power assembly (3100). Alternatively, medicaldevice (6010) may detect the coupling of power assembly (6012) with themedical device (6010) in any other suitable fashion as will be apparentto those of ordinary skill in the art in view of the teachings herein.In the example shown in FIGS. 29 and 30, after the medical device (6010)detects the coupling of power assembly (6012) with medical device(6010), working assembly (6014) begins an interrogation cycle at (block6152) by sensing and/or observing the polarity of the power assembly(6012) with the polarity sensing device (6018), for example. If thepolarity of the power assembly (6012) matches the polarity of theworking assembly (6014) (block 6154), the working assembly (6014) powerson (block 6156). After powering up, the medical device (6010) maydetermine if there is still a match between the polarities of the device(6010) and the power assembly (6012) (block 5158) and then initiate avoltage and current profile associated with the device (6010) in orderto operate the working assembly (6014) (block 6160). The voltage andcurrent profile associated with the working assembly (6014) may beconstant or variable, and may be stored on a database, such as adatabase or other storage medium on a memory (not shown). The memory maybe present on or in the device (6010). Alternatively or additionally,the database or part of the database may be in a nearby or remote memoryand accessed according to methods that will be apparent to those skilledin the art. Additionally or alternatively, working assembly (6014) orpower assembly (6012) may be configured to communicate electronically(wired, wirelessly, or otherwise) with other sources of information(e.g., manufacturer's specifications) in order to discover and/orinitiate an operational profile associated with the working assembly(6014).

In some examples, after powering on, but before (or during) theinitiation of the voltage and current profile (e.g., block 6160), theworking assembly (6014) may optionally observe or sense at least onephysical, electric, electronic, or other characteristic of the powerassembly (6012), including the response of the power assembly (6012) tothe working assembly (6014) being powered on (block 6166). The workingassembly (6014) may then collect and store this information (block6168). In some examples, the working assembly (6104) has the ability toobserve or sense other certain physical, electrical, electronic, orother characteristics of the power assembly (6012) to which is connectedand adjust (or maintain) the polarity of the terminals (6018 a, 6018 b)accordingly. For example, the working assembly (6014) may be configuredto sense other electrical characteristics of the power assembly (6012)such as internal resistance, for example. In addition or in thealternative, the device (6010) may include one or more inductancesensors configured to sense adjacent metallic members on interface(6017) of the power assembly (6012) when the power assembly (6012) isconnected to or adjacent to the working assembly (6014). Therefore, theinductance sensor(s) may sense the presence (or lack thereof) and/orlocation of metallic contacts, for example, of the power assembly(6012); and determine that it is connected to a particular known powerassembly (6012). Other sensors could be employed to sense the physicalcharacteristics (e.g. shape, size, etc.) of the body of the powerassembly (6012), for example. For instance, the working assembly (6014)could include could include switches or sensors to detect mechanical orother features of the body of the power assembly (6012). Additionally oralternatively, the working assembly (6014) could include bar codereaders, radiofrequency identification, or other electrical orelectronic devices or sensors that could be used to identify at leastsome characteristics of the power assembly (6012).

Referring back to block 6154 of FIG. 30, if the polarity of the powerassembly (6012) does not match the polarity of the working assembly(6014), the polarity of the terminals (6018 a, 6018 b) is switched(block 6170) and the response of the working assembly (6014) or othersensed characteristics of the power assembly (6012) may be collected andstored (block 6171) in a memory. In some examples, the electricalcontacts of the terminals (6018 a, 6018 b)) of the working assembly(6014) are moved physically with the goal of properly aligning thecontacts of the working assembly (6014) with the contacts of the powerassembly (6012). Alternatively, the polarity of the terminals (6018 a,6018 b) may be switched by switches (6020, 6022, 6024, 6026). Once thepolarity of the terminals (6018 a, 6018 b) has been switched, theworking assembly (6014) may then begin another interrogation cycle,starting at (block 6152), by observing the polarity of the powerassembly (6012) as described herein above. If, however, the workingassembly (6014) has already performed a certain number of interrogationcycles, the device (6010) may not switch polarity of the terminals (6018a, 6018 b) as shown in (block 6170), and may instead provide an errorwarning to the user (block 6172) and/or suspend operation (block 6174).The error warning may be provided by a visual, audio, and/or anotherindicative manner to the user and may be provided on one or both of thepower assembly (6012) or the working assembly (6014); or on a deviceconnected to one of the power assembly (6012) or the working assembly(6014). The number of interrogation cycles before providing an errorwarning may be two such that the working assembly (6014) has attemptedto properly electrically connect with the power assembly (6012) byswitching between the first and second polarities. However, the numberof interrogation cycles may be a different amount than two, and may bemany more.

In some examples, the working assembly (6014) is configured to adapt inthe event that it cannot properly electrically connect to the powerassembly (6012) (e.g., where the working assembly (6014) is unsuccessfulin aligning the polarity of its contacts with the polarity of thecontacts of the power assembly (6012)). While the flowchart shows thatthe collection and storage of information occurs at blocks 6171 and6168, in other examples such information may also be collected andstored at other times during, before, or after the interrogation cycle.Moreover, the working assembly (6014) may collect and store informationwhether or not it is able to successfully electrically connect to thepower assembly (6012) at any point during an interrogation cycle. Theworking assembly (6014) may optionally communicate the storedinformation to a database to add the observed characteristics of thepower assembly (6012) to the database at various times during theinterrogation cycle.

The working assembly (6014) may use the stored information in asubsequent attempt to match the polarity of the power assembly (6012) towhich it is connected. It may store the power assembly (6012)information for later use for itself or other power assemblies (6012),or both. If using the information in a subsequent attempt to match thepolarity of the power assembly (6012), the working assembly (6014) maypower down and subsequently power up and begin another interrogationcycle at, for example, (block 6152). In some examples, powering theworking assembly (6014) on and off may allow software and/or algorithmswithin the working assembly (6014) (e.g., in a processor) to adapt andupdate in order to attempt to match the power assembly (6012). In someexamples, the step(s) of collection and storage of such information maybe performed using a memory on the working assembly (6014) itself, whichmay then communicate to parties such as the device designer andmanufacturer. The information may be stored and used in any software oralgorithms used in a working assembly (6014) such as one of the examplesdescribed herein. Additionally or alternatively, the information may beconveyed to a central processor or database that may communicate thisand other information to other devices in manners that will beunderstood by those skilled in the art.

V. Miscellaneous

It should be understood that any of the examples described herein mayinclude various other features in addition to or in lieu of thosedescribed above. By way of example only, any of the examples describedherein may also include one or more of the various features disclosed inany of the various references that are incorporated by reference herein.

It should be understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions described above may be designed to be disposed of after asingle use, or they can be designed to be used multiple times. Versionsmay, in either or both cases, be reconditioned for reuse after at leastone use. Reconditioning may include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, someversions of the device may be disassembled, and any number of theparticular pieces or parts of the device may be selectively replaced orremoved in any combination. Upon cleaning and/or replacement ofparticular parts, some versions of the device may be reassembled forsubsequent use either at a reconditioning facility, or by a userimmediately prior to a procedure. Those skilled in the art willappreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometric s, materials, dimensions, ratios,steps, and the like discussed above are illustrative and are notrequired. Accordingly, the scope of the present invention should beconsidered in terms of the following claims and is understood not to belimited to the details of structure and operation shown and described inthe specification and drawings.

I/we claim:
 1. A method of operating a medical device, comprising: (a)connecting a secondary battery pack to the medical device, wherein thesecondary battery pack includes a processor configured to emulate atleast one electrical characteristic of a primary battery pack with atleast one different electrical characteristic than the secondary batterypack; (b) receiving an interrogation input from the medical device withthe processor of the secondary battery pack; (c) sending a responseoutput to the interrogation from the processor to the medical device,wherein the response output emulates an expected response outputassociated with the at least one different electrical characteristic ofthe primary battery pack; and (d) initiating an operational profileassociated with the medical device.
 2. The method of claim 1, furthercomprising storing the interrogation input.
 3. The method of claim 2,further comprising transmitting the stored interrogation input to aremote database.
 4. The method of claim 3, further comprising: (a)removing the secondary battery pack from the medical device; (b)coupling the secondary battery pack to a docking station to charge thesecondary battery pack, wherein the stored interrogation input istransmitted via the docking station.
 5. The method of claim 1, furthercomprising accessing a database of stored interrogation inputs todetermine how to respond to the interrogation input.
 6. The method ofclaim 1, wherein sending a response to the interrogation furthercomprises sending a signal including at least one expected responsecharacteristic, wherein the at least one expected responsecharacteristic is chosen from the group consisting of the following:resistance, voltage, current, and load.
 7. The method of claim 1,further comprising indicating an error to a user when the secondarybattery pack is unable to send an expected response output.
 8. Themethod of claim 1, further comprising storing the interrogation input.9. The method of claim 1, further comprising reprogramming the processorof the secondary battery pack when the secondary battery pack is unableto send a response output that emulates the at least one differentelectrical characteristic.
 10. The method of claim 1, wherein theresponse output emulates an expected effective series resistance R_(S)associated with the primary battery pack.
 11. The method of claim 10,wherein sending a response output to the interrogation from theprocessor to the medical device further comprises providing a loadvoltage V_(L) associated with the primary battery pack, whereinV_(L)=VR_(L)/(R_(S)+R_(L)), wherein R_(L) represents a load resistanceof the primary battery pack.
 12. The method of claim 1, furthercomprising updating software and/or an algorithm of a processor of thebattery pack based on the interrogation input.
 13. The method of claim12, further comprising the step of powering the medical device on andoff before the step of updating software and/or an algorithm of theprocessor of the battery pack.
 14. The method of claim 1, furthercomprising communicating the interrogation input to a database ofinterrogation inputs.
 15. The method of claim 1, further comprising thesteps of: (a) accessing a database of stored interrogation inputs; and(b) updating software and/or an algorithm of a processor of the batterypack based on at least one of the saved interrogation inputs.
 16. Asecondary battery pack, comprising: (a) a battery; (b) an electricalinterface configured to electrically couple the battery with anelectrical interface of a medical device; (c) a processor; (d) a sensorconfigured to receive an input signal from the electrical interface; and(e) a regulator configured to regulate at least one characteristic of anelectrical signal communicated from the battery to the interface;wherein the sensor is configured to communicate at least the inputsignal to the processor; wherein the processor is configured to commandthe regulator to regulate the at least one characteristic of anelectrical signal communicated from the battery to the interface inorder to emulate at least one electrical characteristic of a primarybattery pack that is different from an electrical characteristic of thesecondary battery pack.
 17. The secondary battery pack of claim 15,wherein the processor is configured to command the regulator to regulatea voltage of the electrical signal communicated from the battery to theinterface in order to emulate the internal resistance of the primarybattery pack.
 18. The secondary battery pack of claim 16, wherein the atleast one electrical characteristic of the primary battery pack is aninternal resistance of the primary battery pack.
 19. The secondarybattery pack of claim 16, further comprising an NPN pass transistorbetween the regulator and the interface configured to emulate an outputimpedance of the primary battery pack.
 20. A battery pack, comprising:(a) a battery; (b) an electrical interface configured to electricallycouple the battery with an electrical interface of a medical device; (c)a processor; (d) a sensor configured to receive an input signal from theelectrical interface; (e) a voltage regulator configured to regulate thevoltage of an electrical signal communicated from the battery to theinterface; and (f) a NPN pass transistor configured to regulate theimpedance of the electrical signal communicated from the battery to theinterface; wherein the sensor is configured to communicate at least theinput signal to the processor; wherein the processor is configured tocommand the voltage regulator to regulate the voltage of the electricalsignal communicated from the battery to the interface in order toemulate at least one electrical characteristic of a primary battery packthat is different from an electrical characteristic of the secondarybattery pack.